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Operator’s Manual Serial Number Range: Use with Model Numbers: Starting: 204000 B5-440-36 Ending: See Introduction Chapter B5-440-48 B5-540-48XL WARNING BF-030-48 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 must be kept with the vehicle.
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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 12/28/2016 Revision E, 3/5/2018 Contents subject to change without notice ®...
MB-440-07 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.
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:...
Taking Delivery of Your Charging Your Vehicle Vehicle Generic Safety Guidelines .....48 What To Do If a Problem is Charging Receptacle (BIGFOOT XL)... 49 Found ..........16 Charging Time ........50 New Battery Break-In ......50 Driver Training AC Power Source ........ 50 Driver Qualifications ......
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Changing a Tire/Wheel Assembly ..72 Tire Rotation ......... 73 Replacing a Tire ........73 Brake Fluid Level ......74 Cleaning ..........75 BIGFOOT Standard Specifications BIGFOOT XL Standard Specifications Index Page 6 B5-440-36 / B5-440-48 / B5-540-48XL / BF-030-48 Operator Manual...
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.
MB-440-07 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. A p p r o v e d O p e r a t o r The operator shall be seated in the operator seat with back up against Position the operator seat back cushion.
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MB-440-07 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.
MB-440-07 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.
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.
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 are at your own risk.
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.
MB-440-07 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.
MB-440-07 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 The vehicle identification number can be found in the location(s) shown below: B5-440-36 / B5-440-48 / B5-540-48XL / BF-030-48Operator Manual Page 15...
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.
• 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 B5-440-36 / B5-440-48 / B5-540-48XL / BF-030-48Operator Manual Page 17...
MB-440-07 Vehicle Controls INSTRUMENT PANEL Start Switch Directional Control Switch #1: The Start switch turns on the vehicle #2: Direction Control Switch electrical control system. This switch may or This switch determines the direction of travel. may not require a key to operate. Rotate the Your vehicle will have one of two types of switch switch clockwise to turn the vehicle system depending on when it was manufactured.
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MB-440-07 Hi-Low Speed Switch Headlight Switch #3: Push on the bottom of the High/Low switch #6: Push the top of the headlight switch to turn (turtle) for slow vehicle speed. Push on the top the lights on. Push the bottom of the switch to of the switch (rabbit) for normal speed.
MB-440-07 OPERATOR CONTROLS Throttle Pedal The throttle pedal is located to the right of the brake pedal. It controls the speed of the vehicle and operates similar to the throttle pedal in an automobile. Depress the pedal to increase speed and release the pedal to decrease speed.
Park Brake, Automatic Electric The automatic electric park brake is standard on BIGFOOT XL and optional on the BIGFOOT. The automatic electric park brake will be applied whenever the vehicle is not in motion. While coasting or using the foot brake, the motor speed control monitors the motor rpm, the park brake will be applied after the motor stops rotating.
MB-440-07 Adjustable Seats WARNING DO NOT attempt to adjust the driver or passenger seats while the vehicle is in motion. Adjusting the seat while in motion could result in sudden and violent uncontrolled movement of the seat. The sudden movement of the seat could cause the driver to lose control of the vehicle or eject the occupant from the vehicle resulting in severe personal injury and/or property damage.
MB-440-07 AVAILABLE DASH DISPLAYS SmartView 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 and continued on the following page. BSI: A bar graph representing the current state of The Hour Meter has three functions: Key Hours,...
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MB-440-07 Maintenance Monitor: Note: The Maintenance Monitor function is optional. The Maintenance Monitor function can be turned ON or OFF by your dealer. 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.
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MB-440-07 Display Flash Message Action F22001 Seat Fault Operator presence switch is open. Confirm driver seat properly positioned. F22002 Two Direction Fault Refer to dealer for repair. F22003 SRO Fault Throttle pedal pressed without direction selected. F22004 Sequence Fault Throttle or direction selected at power up. F22006 Inch Fault Inching switch active along with any drive...
MB-440-07 ClearView Display The ClearView display is a multi-function dashboard graphics display that functions as a Speedometer, Trip Odometer, Battery Status Indicator, Vehicle System Status Monitor, and Control System Diagnostics. The three buttons on the right side of the display are used to access all of the available screens and functions.
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MB-440-07 ClearView Dash Display Screens The Main Screen displays the following: • Speedometer • Total Hours • Trip Odometer • Direction Selected (N=OFF, D=Forward, R=Reverse • Battery Status Indicator (BSI) • Battery Water Reminder Details regarding each of these items can be found later in this section.
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MB-440-07 The Time to Distance screen displays how long it takes to drive a predefined distance. Also included on this screen are the total hours of operation. The Fault Log screen displays the fault log history. The “ID” column is the fault ID code. Then “No”...
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MB-440-07 Fault Messages on the Dash Display An example of a typical control system fault message is shown to the right. The following list is the list of faults that can be corrected by the driver/operator. Any other fault should be referred to a qualified technician for repair.
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MB-440-07 Additional fault information can also be viewed on the display. When a fault is displayed, press any one of the three buttons to open the button navigation window and then press the FltHlp button to display the help screen for the fault currently displayed.
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MB-440-07 USB Port The BIGFOOT vehicles have a USB charging port as standard equipment. This port allows the vehicle operator to charge devices (for example, a smartphone or tablet). The dual-port design is capable of charging two devices at the same time.
MB-440-07 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.
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MB-440-07 • 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. •...
Safety seat belts should only be installed on vehicles equipped with Taylor-Dunn approved Operator Protective Structure (OPS) such as a steel cab or cage. Fiberglass cabs or sun tops do not qualify as an OPS.
Taylor-Dunn recommends that all safety belt assemblies used in vehicles involved in a collision be replaced. However, if the collision was minor and a qualified technician finds that the belts do not show damage and continue to operate properly, they do not need to be replaced.
MB-440-07 Starting Before operating this vehicle: Refer to General Safety Guidelines at the beginning of this chapter. Note: This vehicle is equipped with a charger interlock which is designed to disable the vehicle from being driven while the AC charger cord is plugged into a functioning power source. Note: This vehicle is equipped with a operator presence switch which disables the vehicle when the driver seat is not occupied.
MB-440-07 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 chapter. WARNING DO NOT exceed the maximum rated speed for your vehicle, locally imposed speed limits, or the safe operating speed for conditions.
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MB-440-07 Stopping Release the throttle pedal and use your right foot to press the brake pedal. The amount of force required to stop the vehicle will vary depending on the environment and load on the vehicle. This vehicle is equipped with regenerative (regen) braking. Regen braking uses the stored energy of the moving vehicle to generate electricity.
This will not cause damage to the vehicle as this is an active part of the vehicle suspension system. WARNING • Use only Taylor-Dunn approved rear cargo accessories. • Do not exceed the load capacity of the vehicle. DO NOT transport passengers in •...
MB-440-07 Battery Disconnect Vehicles without BIB option: A connector is mounted in the battery compartment that allows the battery to be quickly disconnected from the vehicle’s electrical systems. See illustration to the right. Vehicles with the BIB option: A connector for each box is located on the side of the vehicle.
MB-440-07 4-Passenger Foldaway Seat Operation Open the Seat WARNING 1) Place the Directional Control switch in the center “OFF” position (neutral). 2) Turn the Start switch OFF. 3) Set the park brake. 4. Stop the vehicle on a level surface, set the direction control switch in the center OFF position and set the park brake.
There are numerous variations of the dump bed place. Severe bodily injury will result if the that are available for the BIGFOOT models. bed lowers unexpectedly. Although the physical design varies, the operation is basically the same.
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MB-440-07 Operation WARNING Do not place any body part underneath a raised bed unless the bed prop rod is in place. Severe bodily injury will result if the bed lowers unexpectedly. The dump bed is operated hydraulically through two push button switches. The actual location of these switches will vary depending on the type of dump bed.
• 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.
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MB-440-07 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: •...
MB-440-07 Park Brake Bypass Switch WARNING The park brake should be disabled for servicing or towing procedures only. Do not operate the vehicle while the automatic park brake is disabled. Operating the vehicle with the automatic park brake disabled could lead to severe bodily injury and/or property damage.
WARNING The only personnel authorized to remove the automatic electric park brake from 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.
MB-440-07 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.
Connection of AC power to a contaminated receptacle may result in electric shock, sever personal injury or death. The BIGFOOT XL has an AC charging receptacle mounted on the rear panel. The receptacle will accept any standard industrial rated grounded cord with a NEMA 5-15 receptacle (see illustration below).
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. Page 50...
MB-440-07 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 LEDs are off. Switching voltage when any of the LEDs are on will result in damage to the charger. Sealed Lead Acid batteries (SLA) must be charged with a charger configured for SLA batteries.
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MB-440-07 Charging with the Signet Charger Note: It is recommended that the charging cycle be allowed to complete normally WARNING before disconnecting the AC power cord. A beeping noise from the charger is an Refer to grouped safety warnings and indication of a fault during the charging cycle.
MB-440-07 Lester Summit Charger NOTICE Confirm the chargers active profile is the same type as the batteries installed in the vehicle. Charging with an incorrect profile will result in premature failure of the batteries. The charging profile code is the last two characters in Lesters part number.
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MB-440-07 Charging with the IC650 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.
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Status LED 3 Condition Lamp Lamp Slow Flash Not a valid code for Taylor-Dunn charging systems Slow Flash Charger overheated Slow Flash Low battery voltage. Must be > 10 volts to start. Slow Flash AC power interrupted during charge cycle. Will restart when...
MB-440-07 Lester Summit II Charger Description of Operation The Summit II charger is designed as an automatic charger. It is available with charging profiles for SLA and FLA batteries. Refer to the factory specifications on the charger for the type of battery it was configured for when manufactured.
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MB-440-07 Charging, Summit II 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.
MB-440-07 Delta-Q QuiQ Charger NOTICE Description of Operation Confirm the chargers active profile is the same type as The Delta-Q QuiQ is designed as an automatic charger. It is the batteries installed in the vehicle. Charging with available with charging profiles an incorrect profile will result in premature failure for SLA and FLA batteries.
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MB-440-07 1) Ammeter • Solid: Displays scale of output during bulk phase. • Flashing: Output has been reduced due to high internal charger temperature. • No battery connected: Displays charge profiles 1-6. 2) Bulk Charge Indicator • Solid: Bulk charge phase completed (80% charged) and is in absorption phase.
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MB-440-07 Troubleshooting Instructions If a fault occurs, count the number of flashes between pauses and refer to the table below. Note: If there is no discernible pause then it is an indication of fault code 1. FLASHES CAUSE SOLUTION Check battery size and condition. This fault will clear automatically High battery voltage once the condition has been...
MB-440-07 Delta-Q IC650 Charger NOTICE The Delta-Q IC650 is designed as an automatic charger. It is Confirm the chargers active profile is the same type as available with charging profiles the batteries installed in the vehicle. Charging with for SLA and FLA batteries. The an incorrect profile will result in premature failure charger turns itself on when it is of the batteries.
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MB-440-07 Diagnostic Trouble Codes Code Description Solution E-0-0-1 Battery high voltage Possible causes: wrong battery voltage for charger, other charger E-0-2-1 also attached, resistive battery. Possible solutions: check the battery voltage and cable connections. Check battery size and condition. This error will automatically clear once the voltage is in range.
MB-440-07 Storing and Returning to Service Both storing your vehicle and returning it to service should only be performed by authorized personnel. NOTICE Storing Your Vehicle • Clean the batteries, then fill and charge before Storing batteries that are putting the vehicle in storage. Do not store batteries discharged or allowing stored in a discharged condition.
MB-440-07 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. • Smooth and proper operation of seat belts (if equipped). •...
MB-440-07 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.
MB-440-07 Brake Interlock Switch Sit in the operator position, turn the start switch ON, select a direction, and slowly press the throttle pedal. • The vehicle should operate normally. While operating at a slow speed; press the brake pedal with your left foot. •...
MB-440-07 Maintenance Schedule Maintenance shall 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.
MB-440-07 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.
MB-440-07 Cleaning WARNING 1) Refer to battery warnings at the start of this chapter. 2) Place the Directional Control switch in the center “OFF” position (neutral). 3) Turn the Start switch OFF. 4) Set the park brake. 5) Place blocks under the front or rear wheels to prevent vehicle movement. 6) Disconnect the battery main positive and negative cables or disconnect the main battery plug.
MB-440-07 BATTERY INSPECTION BOX The Battery Inspection Box (BIB) is optional and may not be installed on your vehicle. The BIB allows the vehicle operator to inspect and maintain the batteries without removing the deckboard. There are two BIB’s, one on each side of the vehicle. Slide the BIB Out Disconnect the battery connector.
MB-440-07 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.
MB-440-07 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 struck by other vehicles.
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: •...
MB-440-07 BRAKE FLUID LEVEL WARNING • Only use DOT 3 brake fluid from a new sealed container. • DOT 3 brake fluid is corrosive and will damage paint finishes. • Dispose of brake fluid in accordance with local state and federal regulations. •...
MB-440-07 CLEANING Glass Battery Charger The front, rear, and hard door windows are made The battery charger gets hot during normal operation and it is important that the cooling fins of standard automotive glass and can be cleaned with any standard household glass cleaner. or vents are not caked with mud or dirt.
MB-440-07 BIGFOOT Standard Specifications Models: B5-440-36 (36V) and B5-440-48 (48V) ITEM SPECIFICATION Occupancy 1 Driver, 1 Passenger Dimensions 130.5 L x 44 W x 51.5 H Inches 3,314.7 L x 1,117.6 W x 1308.1 H Millimeter Turning Radius 137 Inches (3,479.8 Millimeters) Ground Clearance 5.5 Inches (139.7 Millimeters)
48V Built-in, 17 amp SCR, 115 VAC, 1kW w/interlock Note: The above table is a Standard Vehicle Specification for the BIGFOOT XL model. This table does not reflect information for special order vehicles or after market revisions. Specifications subject to change without notice.
Stopping Display, Vehicle Status Regen Towing Trailers Draw Bar Pull Regen braking Driver Training Regenerative braking Driving in Forward Returning to Service Driving in Reverse Web site, Taylor-Dunn Dump Bed, Hydraulic Windshield Wiper Switch Dump Bed, Manually Lower Index 78...
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MB-440-07 WARNING CALIFORNIA Proposition 65 Warning Operating, servicing and maintaining a passenger vehicle or off-road 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.
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