Taylor-Dunn B5-540-48XL Service And Replacement Parts Manual page 88

Motor Controller
REMOVE/INSTALL
WARNING
This section is one section of a complete service
manual. Before starting any procedure, read all
warnings and instructions that are located in the
Service Guidelines chapter.
NOTICE
Do not allow the wires to rotate while removing
terminal hardware.
Internal electrical connection will be damaged if the
terminal stud rotates.
It may be required to remove the control panel from the
vehicle for this procedure.
Remove
1: Turn the start switch OFF.
2: Disconnect the batteries.
3: While holding the wires so that they do not rotate,
remove the terminal bolts.
4: Disconnect the logic connector.
5: Remove the four bolts holding the controller to
the panel and remove the controller.
Note: If a heat sink is installed, then these bolts
may also hold the heat sink to the panel.
Install
1: Thoroughly clean the controller base, mounting
plate, and heat sink.
2: Apply thermal transfer compound to the controller
base and heat sink.
3: Install the controller to the mounting plate.
4: Attach the wires to the studs and torque per
specification listed in the table at the end of this
section.
Note: DO NOT allow the wires to rotate while
torquing the bolts (see notice above).
5: Install silicon dielectric grease (94-422-10, 5.3
ounce tube) into the harness receptacle and
reconnect to the controller.
6: Reconnect the batteries and test drive.
WARNING
The motor controllers are programmed to match the
vehicle configuration.
DO NOT move a control to another vehicle unless the
vehicle configurations are identical.
Any changes to the vehicle configuration may require
reprogramming the controller.
Installing a controller programmed with improper
settings may result in damage to the controller or
electrical system which may lead to unsafe vehicle
operation causing severe bodily injury and/or
property damage.
Page 88
B5-440-36 / B5-440-48 / B5-540-48XL / BF-030-48
INSPECT
Receptacles
The inside of each receptacle should be clean and free
of any debris. Use aerosol electrical cleaner if required.
Base Plate
The base plate should be flat. If required, sand with 150
wet sandpaper to remove any raised areas.
Terminal Ends
The wire insulation at each terminal should be smooth
and free of any sign of heat. Any indication of heat is a
result of a loose connection at the terminal. This could
have been a loose bolt or a faulty crimp. It is recommend
to replace the cable terminal end.
Note: A loose bolt could result in damaging the
terminal crimp.
TROUBLESHOOTING
Troubleshooting control system is not included in this
manual.
All electrical troubleshooting information is included in
a separate manual "Troubleshooting Electric Vehicles".
This manual was provided on the original vehicle CD.
A hard copy can be purchased from your authorized
Taylor-Dunn distributor or can be downloaded from the
Taylor-Dunn web site.
MB-440-06