Motor Controller; Inspect; Troubleshooting - Taylor-Dunn SC-090-24 Operation, T Roubleshooting And Replacement Parts Manual

Motor Controller

1) Make sure the key-switch is in the "OFF"
position, then remove the key.
2) Place the forward-reverse switch in the
center "OFF" position.
3) Set the park brake.
4) Place blocks under the front wheels to
prevent vehicle movement.
5) Disconnect the main positive and negative
cables at the batteries.
REMOVE/INSTALL
NOTICE
Use a backup wrench on the terminal bolts. Failure
to use a backup wrench may result in breaking the
terminal seal and premature failure of the controller.
It may be required to remove the control panel from the
vehicle for this procedure.
Remove
6: Using a backup wrench, remove the four terminal
bolts and wires.
7: Disconnect the wires from the KSI and #2
terminals.
8: If equipped with the 7-pin in-line connector,
disconnect it.
9: Remove the four bolts holding the controller to
the panel and remove the controller.
Install
1: Thoroughly clean the controller base and
mounting plate.
2: Install the controller to the mounting plate.
3: Attach the wires to the studs and, using a backup
wrench, torque per specification listed in the
table at the end of this section.
4: If equipped with the 7-pin in-line connector, install
silicon dielectric grease (94-422-10: 5.3 ounce
tube) into the harness plug before connecting to
the controller.
Page 2

INSPECT

Inspect the area around all of the terminals for cracked
or separated potting compound.
Inspect the surface of each terminal for corrosion.
Any cracks or corrosion may be an indication that the
terminal seal is broken and may result in premature
failure of the controller.
Check the adjustment screw plugs for correct torque.

TROUBLESHOOTING

Troubleshooting the control system is not included in
this manual.
All electrical troubleshooting information is included in
a separate manual "Troubleshooting Electric Vehicles".
The troubleshooting manual was provided on the original
vehicle documentation CD. A replacement CD or hard
copy can be purchased from your authorized Taylor-Dunn
distributor or can be downloaded from the Taylor-Dunn
web site.