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E-322 OK - 313 Velocity

1. SNOILJO ONIANVG doHinv 62 20 8002 LO NOISH3A SNOILdO uu OV MOOTTHSLINI 1 uoarens 9 8 ISH VOL v e3 3 o e IVdlIONISMd anNJF DVINOD HOLOV LNOO NIVA O ZW OPTIONS 940 BLK RE 4 N b RED BLK WHT WHT wHT n a 9 BLK k OLA 59 5 r4 ER 1 62X NYS cis Ly 94 Spare Parts 44 Spare Parts PARTS LIST NO DESIGNATION REF QTY SEPEX SPEED CONTROL 1243 4320 1 Bl STROBE LIGHT 1 B2 HORN ki 1 B3 REVERSE ALARM 1 HEADLIGHT 2 E2 A B TAIL BRAKE LIGHT i 2 E3 A B AMBER FRONT LIGHT 2 FI A B C FUSE 15A 246108K 3 F3 CIRCUIT BREAKER 150A 3107000002 1 F5 DIODE BRIDGE 3669027 1 F6 FUSE 30A 4890028 1 1 1 G2 BATTERY CHARGER 1 KI FLASHER RELAY 3069004 1 K2 110 VAC RELAY 366213 RELAY BASE 246216 RELAY RETAINING CLIP 246216C M2 SEPEX MOTOR 1 M4 WIPER MOTOR 1 7 ki PI INDICATOR BDD HOUR METER pi 1 RI ACCELERATOR 2142100001 1 PLASTIC GEAR 367015 1 MICROSWITCH 3
2. Align the front wheel straight Install the pitman arm TOE IN ADJUSTEMENT With the wheels in straight forward direction measure the inside left to right distance between the front tires at the front and rear of the tires Turn the rear tie rod until the distances are equal and tighten the two lock nuts on the tie rod REMOVING amp GREASING OF FRONT HUBS required once a year Remove dust cap and cutter pin unscrew nut remove hub Inspect bearings and races for wear and replace worn bearings Replace the seal Pack the hub with wheel bearing grease and re assemble ADJUSTING FRONT HUBS Tighten spindle nut to 30 ft lb to seat the bearing and back off the nut to the next slot Install a new cutter pin and the dust cap 14 Maintenance BATTERY MAINTENANCE WARNING It is the responsibility of the owner of this vehicle to ensure that the service technicians are properly trained read and obey the safety rules and guidelines in this manual ANSI B56 Maintenance operations must be made by properly trained service technicians only Before any maintenance work park the vehicle on a flat level surface turn off all the switches set to neutral remove the key lift the wheels off the ground and secure with jack stands of adequate capacity Keep charger disconnected while doing any maintenance work Always wear a face shield and scarf when working around ba
3. Dimensions _ 280x245x110cm 11 X97x43 Voltage max V I 100 Weight 5 kg 11 Ibs wi standard outpu Current max A 42 Environmental e Enclosure IP46 Battery Tyne 0 0 m Operating 30 C to 50 C 227 16 122 F derated Battery Type Specific to selected d algorithm x Reverse Polarity Electronic protection auto reset Tempajature aske ou Ee Short Ce Elecroniceurentimit Storage Temperature 40 to 70 C 40 F to 158 F AC input connector IEC320 C14 require 21 8m localized cord I AC Input DC output connector OEM specific w 12AWG wire models Voltage max Vrms 85 265 Mans ee uU Na afe Frequency Hz 45 65 Current max Arms 12A 104VAC reduced 20 lt 104V EE ye Current nominal Arms 10A 120VAC SA Q230VAC EV Changing System Equipment _ AO ponr radon 20 98 at nominal input UL 1564 2nd Edition Industrial Battery Charger CSA C22 2 No 107 2 Battery Chargers Industrial Emissions Solid YELLO E 1180 FCC Part 15 ICES 003 7 Unintentional Radiators Class A AN n SED 55011 won Radio disturbance characteristics Class A JS _ YELLOW Ge YELLOW _ EN 61000 3 2 Limits for harmonic current emissions E lash Bargraph ei EN 61000 3 3 Limits of voltage fluctuations and flicker _ lt 80 Charge Indicator ort Flas Immunity gt 80 Charge Indicator Solid YELLOW Long Flash GREEN EN 61000 4 2 Electrostatic discharge immunity
4. PATENT NO 4626750 1243cen2 Manual p n 37044 Rev A October 2002 2 INSTALLATION amp WIRING Controller for the M8 bolts The maximum bolt insertion depth below the surface of the bus baris 1 3 cm 1 2 Bolt shafts exceeding this length may damage the controller The torque applied to the bolts should not exceed 16 3 N m 12 ft Ibs Two 1 4 quick connect terminals S1 and S2 are provided for the connections to the motor field winding WIRING Standard Configuration Figure 3 shows the typical wiring configuration for most applications For walkie applications the interlock switch is typically activated by the tiller and an emergency reverse switch on the tiller handle provides the emergency reverse signal For rider applications the interlock switch is typically a seat switch or a foot switch and there is no emergency reverse EMERGENCY REVERSE 5kQ POT THROTTLE TYPICAL FORWARD REVERSE INTERLOCK n ELECTRO 18 5866 6606 9 O 51 5215 i 0 MAIN KEY CONTACTOR o SWITCH B M B COIL POLARITY emergency reverse wiring check optional PROTECTION DIODE A MAIN FUSE mu gt LI E POWER FUSE 2 Fig 3 Standard wiring configuration Curtis 1243GEN2 controller Curtis 1243e n2 Manual 23 7
5. cifi es par le fabricant de la batterie p ex v rifier s il faut enlever les bouchons des cellules lors du chargement de la batterie et les taux de chargement recommand s Information de S curit lectrique Danger Risque de chocs lectriques Ne pas toucher les parties non isol es du connecteur de sortie ou les bornes non isol es de la batterie Toujours connecter le chargeur une prise de courant mise la terre Ne pas ouvrir ni desassembler le chargeur referer toute reparations aux personnes qualifi s Pas l usage des enfants Operating Instructions Always use a grounded outlet When using an extension cord avoid excessive voltage drops by using grounded 3 wire 12 AWG cord 1 2 The charger will automatically turn on and go through a short LED indicator self test Models 912 xx0x will flash all LED s in an up down sequence Models 912 xx1x will alternatively flash its LED RED GREEN for two seconds If the charger is connected to battery pack a trickle current will be applied until a minimum voltage is reached If the charger is used in an off board application and the charger is waiting to be plugged into a battery pack the charging algorithm number will be displayed for 11 seconds see Check Change Charging Algorithm before ultimately displaying an under voltage fault fault disappears when plugged into battery pack Once a minimum battery voltage is detected the charger will ent
6. 100 Crago Indicator Song SEES EN61 000 4 3 8 Radiated radio frequency EMF immunity ED 4 61000 4 4 Electrical fast transient burst immunity OPSA z EN610004 5 Surge immunit Bat Temp Compensation Automatic Optional 0 61000 4 6 zt ity Maintenance Mode Auto restart if V 2 1Vpc or 30 days elapse EN 61000 4 11 Volt age variations immunity Installation Instructions AN WARNING The output of chargers with greater than 48V may pose an energy and or shock hazard under normal use These units must be installed in the host equipment in such a manner that the output cable and battery connections are only accessible with the use of a tool by qualified personnel 1 Determine Mounting Location While its sealed nature allows the charger to be mounted virtually anywhere the choice of mounting location and orientation is extremely important For optimum performance and shortest charge times mount the charger in an area with adequate ventilation The charger should also be mounted in an area that will be relatively free of oil dirt mud or dust since accumulations within the fins of the charger will reduce their heat dissipating qualities Optimal cooling also occurs when the charger is mounted on a horizontal surface with the fins vertical More airflow from below the charger will help cool the fins so mounting above open areas or areas with cu
7. DIAGNOSTICS amp TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING The 1243GEN2 controller provides diagnostics information to assist technicians in troubleshooting drive system problems The diagnostics information can be obtained by observing the appropriate display on the handheld programmer the fault message displayed on the Spyglass gauge the fault codes issued by the Status LED or the fault display driven by the controller s fault outputs Fault 1 and Fault 2 Refer to the troubleshooting chart Table 7 for suggestions covering a wide range of possible faults PROGRAMMER DIAGNOSTICS The handheld programmer presents complete diagnostic information in plain language Faults are displayed in the System Faults Menu and the status of the controller inputs outputs is displayed in the Monitor Menu Accessing the programmer Fault History Menu provides a list of the faults that have occurred since the fault history file was last cleared Checking and clearing the fault history file is recommended each time the vehicle is brought in for maintenance For information on 1311 programmer operation see Appendix B If you are using the older 1307 programmer refer to existing documentation SPYGLASS DIAGNOSTICS The eight character LCD on the Spyglass displays a continuous sequence of hourmeter battery state of charge and fault messages Fault messages are displayed using the same codes that are flashed by the LED see Table 8 For e
8. REF DESCRIPTION x d WN Description Housing Axle Service Inc 1 2 Bolt Bearing Cap Shaft input Ring Retaining O Ring Bearing Ball Bearing Ball Plug End Cap Bearing Ball Assembly Gear Intermediate O Ring Gear Final Drive Bearing Ball Assembly Differential Bolt Hex Nut Lock Plate Cover Plug Hex Head Screw Tapping Vent Screw Socket Head Washer Flat Nut Lock Seal Oil Ring Retaining Assy Bearing Tapered Roller Seal Oil Assembly Brake L H Assembly Brake R H Shaft Axle L H Shaft Axle R H Bolt Whee Drum Brake Finished Gasket Seat Spring Kit Input Gear Inc 3 4 5 6 7 Kit Internal Gears Inc 3 10 12 Kit Ball Bearings Inc 6 7 9 13 Kit Carrier Cover Assy Inc 17 18 Kit Assy Shaft amp Bolt L H Inc 30 32 Kit Assy Shaft amp Bolt R H Inc 31 32 33 QTY N a 00 00 KK K 2171300001 2179300001 2116300001 2179300002 2104300002 2102300001 2102300002 2179300003 2102000003 2116300002 2104300003 2116300003 2102000004 2117300001 2179000003 2179000004 2179300004 2179300005 2179300006 2179000005 2179000006 2179000007 2179000008 2104000004 2179000009 2108000001 2104000005 2124000001 2124000002 2173300003 2173300005 2179000010 212
9. all switches set the F R selector to neutral set the parking brake remove the key before leaving the vehicle Maintenance MAINTENANCE Maintenance SAFETY WARNINGS FOR SERVICE TECHNICIANS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY Owner shall comply with OSHA and ANSI ITSDF B56 8 amp B56 9 Standards for vehicle maintenance Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect carriers vehicles tractors and batteries Before any maintenance work park the vehicle on flat level surface turn off all switches remove key lift wheels off the ground and secure with jack stands of adequate capacity Don t connect charger Keep clear from moving parts such as tires sheaves and motor Follow the maintenance instructions applicable to the type of repair maintenance or service Always wear a face shield and gloves when working around batteries Before opening the battery compartment disconnect the charger turn off all switches and remove the key Batteries emit highly explosive gases which greatly increase when charging do not disturb connections or produce sparks around batteries to avoid a battery explosion and acid splashing Battery acid causes severe damage to eyes or skin Flush contaminated area immediately with water Use insulated tools to avoid sparks that can cause battery explosion and acid splashing Use two counteracting tools double wre
10. any cell to avoid electrolyte to be forced out while charging Fill each cell to plate level with distillated or de ionized water before battery charging When the battery is charged the fluid expands and can seep out if overfilled Refill each cell after full charge when the fluid has expanded to its maximum level Reinstall battery caps before charging 15 Maintenance BATTERY MOUNTING A loose battery increases damaging effects of vibrations and is more prone to short out BATTERY DISCHARGE LIMIT Discharging below a 20 state of charge cuts down the battery life and the number of cycles available At 20 state of charge specific gravity of 6V battery should be 1180 and 1220 for industrial battery CHARGING AREA Always charge battery in a well ventilated area set for and approved for charging Never leave a charger connected for more than 20 hours FREQUENCY OF CHARGE When a battery is discharged to its 20 state of charge it is best to charge immediately Batteries require a low current equalization charge min 4 hours at least every week to equalize battery cells improve battery performance and life in number of cycles Never leave a charger connected for more than 20 hours STORAGE Keep the battery from getting cold it would loose its capacity Letthe battery warm up before charging Charge batteries in stored vehicles every month DEFECTIVE BATTERY Check specific gravi
11. capacity e Avoid loose unbalanced or top heavy loads to keep a good stability and prevent overturn Do not load cargo that can fall off the vehicle Do not carry cargo that is longer wider or higher than this vehicle e Always depress slowly the accelerator for smooth acceleration Avoid stunt driving or horseplay e Avoid sharp turns always slow down before turning to prevent vehicle overturn or trailer jack knife Vehicle is more sensitive to overturn and jack knife when traveling on inclines or when carrying a heavy load e Always drive straight up and down the face of an incline never across the face to prevent overturn and trailer jack knife Drive slower and start applying brakes sooner on inclines to adjust for longer stopping distance e Use extra care and drive slowly in reverse in congested areas or on wet or slippery ground e Keep the right under normal conditions Maintain a safe distance from all objects e Slow down and sound the horn when approaching a corner or other blind intersections e Before leaving the vehicle park on a level ground flat surface turn off all switches set the forward reverse switch to neutral set the parking brake remove the key Do not park the vehicle on an incline e Before battery charging park the vehicle in a well ventilated area set for Do not operate it when charging To interrupt a charging cycle disconnect the AC plug disconnecting the DC plug or a battery terminal or operatin
12. direction or energize an N C relay and alarm Turning off and on the vehicle will override the protection for 30 sec The current status remaining operating hours before maintenance of the service down counter is indicated for a period of 5 seconds after the key switch is turned on When it is down to 0 the display flashes After the maintenance reset the counter depress the button on the rear The service counter is factory programmable only 24V UNIT 2469026 36V UNIT 3069038 48V UNIT 4869037 2 Orange key switch 3 Relay 4 Relay 5 Black battery 6 Blue hour counter 8 White battery 56 Addendum ADDENDUM 57 Addendum CURTIS FOOT PEDAL BLUE KEY SWITCH GREEN HOUR METER BLACK POTENTIOMETER WHITE POTENTIOMETER PART NO DESCRIPTION 3062001C ACCELERATOR CURTIS 367008 POTENTIOMETER 2262004C SPRING 2262001C MICRO SWITCH 2262003C LEVER 3662002 CABLE PROTECTOR RESP CLAUDE L MODEL E E 320 360 480 500 NO 321A320001 SER 1018799 TO 1019973 58
13. 0001 3112230001 13 BRUSH SPRING 484010 484010 2450006 2450006 2450006 2450006 14 BRUSH PLATE 484011 484011 2450007 2450007 2450007 2450007 16 LEAD ASSY 484017 484017 N A N A N A N A 17 BRUSH 484009 484009 N A N A N A N A 18 LEAD AND BRUSH ASSY N A N A 2450008 2450008 3112210004 2450008 38 Spare Parts REAR SUSPENSION AND BRAKE 50 3 1311N 3434410 VNVG 0 3 8 2063 1311N 3433410 VNVG 39 Spare Parts REF PART NO 1 2120236001 2 481431 481430 3 2121000005 4 2121000006 5 2122236001 6 2122300001 2122300002 7 2128280001 8 2128280001 9 2129000001 10 2134000001 11 2139000002 12 2139000003 13 2182320002 14 2185280001 15 2185320001 16 2185320002 17 2192320001 18 2192320001 19 2192320001 20 2910000017 21 2910000018 22 2916000002 23 2916280002 24 2916320001 25 2916480001 26 27 28 29 30 31 2183240002 E 302 amp 348 DESCRIPTION DISC RIGHT CALIPER LEFT CALIPER BUSHING LONG BUSHING SHORT MOUNTING PLATE CALIPER LEFT CALIPER SUPPORT RIGHT CALIPER SUPPORT PADS PADS CLIPS FLEX HOXE WASHER BOLT SHACKLE LINK FORD PLATE DANA PLATE GM PLATE 4 LEAF SPRINGS 5 LEAF SPRINGS 7 LEAF SPRINGS HEAVY DUTY BOLT LONG BOLT SHORT U BOLT 1 2 NF X 27 U BOLT 1 2 NF X 3 1 4 U BOLT 1 2 NF X 2 3 4 ID U BOLT 1 2 NF X 4 LD BOLT 5 8 NC X 4 FLAT WASHER 12mm MACHINE SCREW 1 4 NC X 3 8 NYLON NUT 5 8 NC HEAVY
14. 0007 2104300004 2104300005 2117250001 2120236001 481431 481430 2121000005 2121000006 2122300001 2122300002 2128280001 2128280001 2129000001 2134000001 2139000001 2139000002 2139000003 2180240001 2182320001 2185320001 2185488001 2192280001 2200300002 2200300003 2201300007 2201360001 2201320001 2201320007 2201360002 2205250001 2206300003 2206320001 2207000001 2207000002 2207300006 2207320001 2207320009 2208240001 DESCRIPTION BUSHING BUSHING WITH OIL SEAL BUSHING THRUST BEARING TAPER BEAING TAPER BEAING TAPER BEAING OIL SEAL OIL SEAL GEAR DISC RIGHT CALIPER LEFT CALIPER BUSHING LONG BUSHING SHORT LEFT CALIPER SUPPORT RIGHT CALIPER SUPPORT PADS PADS CLIP FLEX HOXE CALIPER PROTECTOR WASHER BOLT SHOCK ABSORBER SHACKLE LINK PLATE PLATE LEAF SPRINGS TUBE SHAFT LEFT SPINDLE LEFT SPINDLE BRAKES AXLE BEAM RIGHT SPINDLE RIGHR SPINDLE BRAKES KING PIN STEERING SUPPORT BOLT PATTERN 2 3 8 STEERING SUPPORT BOLT PATTERN 2 1 4 ROD END LEFT HAND ROD END RIGHT HAND REAR TIE ROD FRONT TIE ROD ARM STEERING WHEEL Front axle with hydraulic disc brakes Front axle with shock absorber 37 PART NO 2208240002 2219250001 2224280001 2224300002 2229300001 2229300002 2229300003 2910000005 2910000006 2910000017 2910000018 2910000019 2910000020 2910000021 2910000022 2910000023 2910000024 2910000025 2910300001 291
15. 002 3102302003 3102480002 3102480003 3102480004 3119000011 HF CHARGER DESCRIPTION 24V CHARGER U S BATTERY 24V CHARGER LIFELINE BATTERY 24V CHARGER GEL 180AH BATTERY 24V CHARGER 27TM BATTERY 36V CHARGER U S BATTERY 36V CHARGER LIFELINE BATTERY 36V CHARGER GEL 180AH BATTRY 48V CHARGER U S BATTERY 48V CHARGER LIFELINE BATTERY 48V CHARGER GEL 180AH BATTERY CONNECTOR C13 51 Spare Parts QuiQ HFIPFC Battery Charger SAVE THESE IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety operating and A installation instructions read before using charger Battery Safety Information Wa rning Use charger only on battery systems with an algorithm selected that is appropriate to the specific battery type Other usage may cause personal injury and damage Lead acid batteries may generate explosive hydrogen gas during normal operation Keep sparks flames and smoking materials away from batteries Provide adequate ventilation during charging Never charge a frozen battery Study all battery manufacturers specific precautions such as recommended rates of charge and removing or not removing cell caps while charging Product Manual for QuiQ 912 24xx 36xx 48xx 72xx Unit 3 5250 Grimmer St Burnaby BC Canada V5H 2H2 Tel 604 327 8244 604 327 8246 www deita g com INFORMATIONS IMPORTANTES DE SECURITE Cons
16. 0300002 2914364001 2916000001 2930000012 DESCRIPTION COVER SPACER HUB HUB DUST CAP OIL SEAL SPINDLE WASHER NUT LEFT HAND NUT RIGHT HAND BOLT LONG BOLT SHORT WHEEL NUT LOCK WASHER 7 8 JAM NUT 7 8 NF JAM NUT 3 4 SPRING PIN 1 3 4 SET SCREW 5 16 NC WHEEL BOLT CASTELLATED NUT 3 4 NF CASTELLATED NUT 1 UNEF BUSHING U BOLT GREASE FITTING BOLT 3 8 NC X 1 BOLT 5 8 NC X 4 BOLT 5 16 NC X 1 1 4 BOLT 5 16 NC X 1 BOLT 7 16 NC X 2 CARRIAGE BOLT 1 4 NC X 3 4 FLAT WASHER 1 4 FLAT WASHER 12mm FLAT WASHER 7 16 COTTER PIN 3 16 X 2 COTTER PIN 7 64 X 2 MACHINE SCREW 1 4 NC X 3 8 NYLON NUT 5 8 NC LOCK WASHER 1 4 LOCK WASHER 5 16 LOCK WASHER 3 8 LOCK WASHER 7 16 HEAV Y NUT 1 2 NUT 1 4 NC NUT 3 8 NC NUT 5 16 NC Spare Parts MOTOR AND DRIVE 10 7 2 7 COMMON PARTS REF DESCRIPTION PART REF DESCRIPTION PART 1 PULLEY 262424 8 MOTOR BASE FORD Contact manuf 2 V BELT 242431 BELT TENSIONER 2152002 3 PULLEY 3651001 9 SEAL 484001 4 3651002 10 BEARING 484003 5 MOTOR BASE GM Contact manuf 11 SNAP RING 484004 6 BELT TENSIONER LONG 2452005 12 NUT WASHER PACK 484006 BELT TENSIONER SHORT 2452003 15 WAVY WASHER 484013 7 PIVOT 2452002 19 HEADBAND 484015 EE HEADBAND KIT A91 107A SPECIFIC REF DESCRIPTION A89 B98 A00 D00 SEPEX DC3 SEPEX DANA DRIVE MOTOR ASS Y 484000 204050 2450002 2450003 311221
17. 09800006 occupants qs seated with seat belt buckled if applicable occupants keep all their body parts inside vehicle occupants keep holding on hand rails wheel chair if applicable i d with tie down straps trail tachment if applic ecured with two chains Before leaving this vehicle park or surface set to neutral set the parking brake turn off all swit and remove the key When a disconnect handle is installed this label is required located in front of handle 4800012 BATTERY DISCONNECT PULL Respectively key switch markings forward reverse selector markings and light switch marking ke 266211 2819321003 1269004 10 Maintenance PERIODIC MAINTENANCE CHECKLIST REVISION 080206 WARNING Maintenance operations must be made by properly trained service technicians Keep clear from moving parts such as tires sheaves and motor Check for all EE protections when applicable and keep cables and wires clear from mechanical and rubbing action Batteries contain sulphur acid that can cause severe burns on skin or eyes When working around batteries wear acid proof protective equipment face shield and gloves Use electrically insulated tools to avoid sparks that can cause battery explosion Before any maintenance work park the vehicle on a flat level surface turn off all switches remove the key lift the wheels off the ground and secure with jack stands of
18. 3000001 2807300001 2174000001 2116300004 2116300005 2102300005 2179300007 2173300002 2173300004 Spare Parts HYDRAULIC DRUM BRAKES REF PART NO DESCRIPTION 1 362841 PLATE CYLINDER 2 362842 BRAKE SHOE 4 362844 SPRING 5 362845 SPRING 6 362846 SPRING 7 362847 SPRING 8 362848 FITTING 9 362849 BLEEDER 10 362850 PISTON 13 362853 ADJUSTER 14 362855 BOLT GRADE 8 15 3612001 LEFT LEVER 3612002 RIGHT LEVER 34 Spare Parts REF PART NO 1 2 2910000015 3 4 2930000012 5 2131100002 6 2131360002 7 2133280001 8 9 2132320001 10 11 2125000001 14 2190000003 HYDRAULIC BRAKE CONTROLS DESCRIPTION Hexagonal nut Yoke Lock washer 14 Lubrication fitting Rubber Lever Push rod master cylinder Hexagonal nut 3 8 16 NF Pivot Included with 212500001 Master cylinder Clevis pin 3 8 x 1 3 32 Cotter pin 3 32 x 1 Spring OTY 35 REF PART NO 2910000014 2910000016 2910000007 2130330001 2129240002 2129000003 2129000001 2910000013 2921000001 DESCRIPTION Clevis pin 5 16 x 3 4 Yoke Cotter pin 3 32 x 1 Flat washer 5 16 Clevis 5 16 x 1 1 2 Handbrake pulling plate Handbrake lever Handbrake cable Clip Yoke Cable stop QTY H ra tA Spare Parts FRONT ASSEMBLY 36 Spare Parts REF GA AR WN PART NO 2100300002 2100300001 2100300003 2103250001 2103300001 2103300002 210330
19. 3269001 Plug 246012A 12V 2469021 24V 2469022 Red Tail Brake light Housing 3069012R Bulb 12V 3117240001 Back up lamp Grommet 3269001 12V 3669012 24V 3669012A Clear lamp 12V 3069012 Bulb 12V 1269008 Pedestral head lamp 12V 2569001 Bulb 12V 2569001B Bulb 24V 4469001 Headlight Left 3111480003 Right 3111480004 Bulb H L 3111480006 Bulb Turn 3111480008 Bulb Mark 3111480007 Headlight Left 3111480003 Right 3111480004 Bulb H L 3117480001 Bulb Turn 3117480003 Bulb Mark 3117480002 Turn signal switch 246050 Multi LED Red Tail Brake Light 3111000006 Grommet 3111000008 Plug 3119000009 Multi LED Back up Light 3111000007 Strobe light 3111000013 Grommet 3111000008 Plug 3119000009 Red Tail Brake light 12V 386002 Horn button VIP 2330014 e Horn button column mount 246210 e Horn button dash mount 266210 lt Horn button 3109250001 Limit switch 3109000029 Horn 12V 246003 24 246013 54 Spare Parts Analog Voltmeter 12V 3069007 24V 2469002 36 48V 3669002 HOBBS Gauge 24V 2469026 36V 3069038 48V 4869037 DC DC converter 10A 12 48V 3069019 DC DC Converter 25A 12 48V 3124000002 72 80V 3124880001 Wiper motor 12V 3113000001 24V 486211 Wiper arm 2800000001 Wiper blade 14 Blade 2800000002 18 Blade 2800000003 Pant
20. 5 113285 083135 029575 043285 TYPE 36LC25 8ET 115 VAC 60 Hz DESCRIPTION CASE ASSEMBLY CASE ASSEMBLY WITH NO HANDLE TRANSFORMER ASSEMBLY CAPACITOR 6 0 MFD 660 VAC HEATSINK ASSEMBLY WITH DIODES FUSE ASSEMBLY AMMETER 0 30 AMP ELECTRONIC TIMER ASSEMBLY RELAY 044845 RELAY TIMER KIT 36 VDC BUSHING 7W 2 INSULATOR FOR DC CORD CORDSET AC 14 3 72 CORDSET AC 14 3 18 CORDSET AC 14 3 114 CORDSET DC NO PLUG 12 2 108 CORDSET DC GREY RUBBER PLUG 12 2 108 CORDSET DC NO PLUG 2 10 AWG 160 CORDSET DC WITH LESTER PLUG CORDSET DC WITH 50 AMP ANDERSON PLUG CORDSET DC WITH 175 AMP ANDERSON PLUG CORDSET DC WITH RING TERMINALS PLUG ASSY DC 50 AMP ANDERSON PLUG PLUG ASSY DC 175 AMP ANDERSON PLUG RECEPTACLE MOTOR BASE 125 15 47 Spare Parts GROUNDED AC INPUT AC CORDSET PORTABLE CHARGER MODEL 07710 02 CAPACITUR HEATSINK ASSEMBLY WITH DIDDES ELECTRONIC TIMER KIT DC CDRDSET WHITE DR RED BLACK BATTERIES FUSE AMMETER CASE GROUND ASSEMBLY Parts list for LESTRONIC II charger MODEL 07710 TYPE 36LC25 8ET 115 VAC 60 Hz PART NO DESCRIPTION 073775 CASE ASSEMBLY 078498 TRANSFORMER ASSEMBLY 023908 CAPACITOR 6 0 MFD 660 VAC 163548 HEATSINK ASSEMBLY WITH DIODES 087765 FUSE ASSEMBLY 041275 AMMETER 0 30 AMP 163695 AMMETER 0 30 AMP 063578 ELECTRONIC TIMER ASSEMBLY RELAY 044845 04484D RELAY TI
21. 67002 1 POTENTIOMETER 367003 1 SPRING 2462008 1 51 KEY SWITCH 246205 1 53 SEAT SWITCH 3109000003 1 CONNECTOR 3109000004 57 FORWARD REVERSE SELECTOR 266211 1 58 LIGHT SWITCH ROCKER TYPE 1269004 1 LIGHT SWITCH PUSH PULL 486002 1 510 HORN BUTTON 1 512 BRAKE LIGHT SWITCH 246207 1 513 FLASHER SWITCH k 1 515 EMERGENCY PUSH BUTTON 3109800001 1 EMERGENCY PUSH BUTTON LABEL 3109800006 1 Ul DC DC CONVERTER 1 HOUR METER CONNECTOR 1 X3 SPEED CONTROL CONNECTOR 1 5 BATTERY CHARGER CONNECTOR 1 29 PVC GROUNDING PLUG YELLOW 80003 YI MAIN CONTACTOR 3104236001 1 Y10 HEATER SOLENNOID 246101 1 STATIC STRAP 2450001 1 Consult Motrec illustrated parts 45 Spare Parts BATTERY CONFIGURATIONS 36V CONFIGURATIONS DES BATTERIES 36V 12V Accessories Ground E 280B LIFT OUT E 320 E 330 E 360 E 300 E 302 E 322 12V Accessories Ground 12V Accessories Ground E 276 E 266 E 266 ROLL OUT 12V Accessories Ground 46 Spare Parts ELECTRONIC TIMER KIT AC INPUT GROUNDED BUILT IN CHARGER MODEL 6430 00 CAPACITOR HEATSINK ASSEMBLY WITH DIODES WHITE OR RED C TRANSFORMER BLACK C o BATTERIES 249 FUSE AMMETER T CASE GROUND ASSEMBLY Parts list for LESTRONIC II charger MODEL 06430 PART NO 073358 186875 096915 023905 163545 087765 041275 096855 044845 020285 025065 113275 138955 085125 127815 095225 080205 086075 08224
22. ED 0 TO 100 100 THROTTLE TYPE THROTTLE TYPE 3 WARM SPD WARM SPEED 0 TO 100 100 THRO DEADBAND Thr Neutral deadband 96 of 5kohms pot 6 MOT WARM MOT WARM X 10 m 10 TO 250 250 THROTTLE MAX Thr Input req d for 100 PWM 5kohm pot 90 MOT HOT MOT HOT X 10 m 10 TO 250 250 THRTL MAP THROTTLE MAP AS 96 30 MOTOR COMP MOTOR ON OR OFF OFF FIELD MIN MIN FIELD CURRENT IN AMPS 7 MAX REV REGEN MAX REV REGEN 100 TO 300 100 FIELD MAX MAX FIELD CURRENT IN AMPS 20 MAX FWD REGEN MAX FWD REGEN 100 TO 300 100 FIELD MAP START Arm current at wich FIELD MAP takes effect amps 70 MIN REV REGEN MIN REV REGEN 100 TO 300 25 FIELD MAP Field winding current as armature current 50 MIN FWD REGEN MIN FWD REGEN 100 TO 300 25 CURRENT RATIO CURRENT RATIO FACTOR OF 1 2 4 OR 8 1 MAX LOAD VOLTS MAX LOAD VOLTS 0 2 TO 5 5 0 2 M1 RESTRAINT MODE 1 RAMP RESTRAINT 1 TO 10 10 MIN LOAD VOLTS MIN LOAD VOLTS 0 2 TO 5 0 0 2 M2 RESTRAINT MODE 2 RAMP RESTRAINT 1 TO 10 10 INT BRAKE DLY INT BRAKE DLY 0 0 TO 8 0 0 0 M3 RESTRAINT MODE 3 RAMP RESTRAINT 1 TO 10 10 FAULT CODE ON OR OFF ON M4 RESTRAINT MODE 4 RAMP RESTRAINT 1 TO 10 10 EMR BRAKE PWM EMR BRAKE PWM ON OR OFF OFF LOAD COMP LOAD COMPENSATION 0 TO 25 0 FIELD CHECK FIELD CHECK ON OR OFF ON PUMP METER PUMP METER ON OR OFF OFF 6 MPH MAX disconnect wire MODE 2 B PIN 9 8 MPH MAX disconnect wire MODE 1 A PIN 14 28 Spare Parts SPARE PARTS 29 Spare Parts BODY REF PART
23. IT THE GREEN LEAD IS GROUNDED AUXILIARY SWITCH IS SHOWN WITH THE TREADLE IN THE UP POSITION SWITCH WILL ACTUATE AT BEGINNING OF TREADLE STROKE SYMBOLS COM N O amp N C ARE TERMINAL MARKINGS AS MARKED ON SWITCH AUXILIARY SWITCH A ADJUSTING SCREW ACTUATOR PIN 12 Maintenance HYDRAULIC amp PARKING BRAKES Revision 2008 02 06 DRUM BRAKES Remove brake drums and check lining wear Replace shoes and springs if the lining thickness is 1 16 2mm or less Turn the brake adjustment to reduce the clearance between lining and drum Wheels must turn free when the pedal is released DISC BRAKES Check pad linings Replace pads if lining thickness is 1 16 2 mm or less PARKING BRAKE Replace cables and stoppers if cable play exceeds 1 8 4mm Wheels and or differential pinion must turn freely when the parking brake is released On pinion brake use spacers at pad fixed ends to reduce space between pads and pulley to 1mm To install new cables and stoppers insert the new cable through the hand lever end pull the cable out from the brake assembly end insert the stopper on the cable and leave a maximum play of 1mm for a two cable system make sure that cable length is the same at hand lever end tighten 4 ncx3 4 grade 5 bolt in stopper at 8 LbFt 1 INM torque cable must extend 1 5 4cm out of the cable stopper cut cable excess Once cable play has been checked and or adjusted turn the kno
24. MER KIT 36 VDC 020288 BUSHING 7W 2 INSULATOR FOR DC CORD 119238 CORDSET AC 095228 CORDSET DC 2 410 AWG 160 NO PLUG 085128 CORDSET DC NO PLUG 080208 CORDSET DC WITH LESTER PLUG 127815 CORDSET DC WITH GREY LESTER PLUG 086075 CORDSET DC WITH 50 AMP ANDERSON PLUG 082248 CORDSET DC WITH 175 AMP ANDERSON PLUG 105368 CORDSET DC WITH 130 50 AMP amp EZ GO PLUG 083138 PLUG ASSY DC 50 AMP ANDERSON PLUG 029575 PLUG ASSY DC 175 AMP ANDERSON PLUG For use with chargers built before Dec 90 For use with chargers built after Dec 90 48 Spare Parts BUILT IN PORTABLE 40 CHARGER ELECTRONICTIMER TRANSFORMER AMMETER CAPACITOR Parts list for LESTRONIC II charger MODEL 09475 PART NO 094775 094765 090415 088495 168235 096855 023905 020085 020285 025065 085115 187715 080675 080695 083295 203315 094345 083135 029575 087745 TYPE 36LC40 8ET 115 VAC 60 Hz DESCRIPTION CASE ASSEMBLY TRANSFORMER ASSEMBLY HEATSINK ASSEMBLY WITH DIODES DIODE ASSEMBLY AMMETER ELECTRONIC TIMER ASSEMBLY CAPACITOR 6 0 MFD 660 VAC BUSHING 8 2 INSULATOR FOR DC CORD BUSHING 7W 2 INSULATOR FOR AC CORD CORDSET AC CORDSET DC NO PLUG CORDSET DC WITH MOLDED PLUG GREY CORDSET DC WITH LESTER PLUG CORDSET DC WITH 50 AMP GREY PLUG CORDSET DC WITH 175 AMP GREY PLUG CORDSET DC WITH 175 AMP YELLOW PLUG CORDSET DC WITH 350 AMP GREY PLUG PLUG ASSY DC 50 AMP ANDERSON
25. MOTREC u 322 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1034667 amp UP Printed in Canada One Year Limited Warranty Effective April 25 2005 MOTREC Inc MOTREC hereby warrants to the Original Retail Purchaser Owner that any of its vehicles shall be free from any defect in materials for a period of 90 DAYS while in the possession of such Original Retail Purchaser This warranty IS NOT TRANSFERABLE to any subsequent Buyer The warranty period is extended to one year or one thousand 1 000 hours which ever first occurs on the electric motor differential parts that bathe in oil and the electronic speed controller MOTREC makes no warranty or representation with respect to the internal combustion engine tires and batteries since their respective manufacturers cover such parts Accessories light gage horn etc electrical contacts switch solenoid contactor relay diodes amp fuses belts amp pulleys filters amp spark plugs lubricants brake linings amp shoes brake drums 8 discs seals seats trim and other items subject to wear are not included in this warranty nor is any item that in MOTREC sole opinion shows evidence of neglect misuse abuse collision or alteration This warranty shall not apply to normal maintenance requirements as described in the User Manual and to damages during shipment The latter is the carrier s responsibility No compens
26. NO DESCRIPTION 1 2383320004 SEAT 1005003 SLIDE ADJUSTERS 2 120003 TRIMMING 3 2314320001 FRONT BUMPER 5 283001 4 80 X 8 PNEUMATIC WHEEL 5 BOLT 283002 4 80 X 8 FOAMFILLED WHEEL 5 BOLT 2807001 16 O D N M SOFT WHEEL 5 BOLT 6 2382320011 BACKREST CUSHION 7 2803300009 LEFT HANDLE 2809300008 RIGHT HANDLE 8 2352330013 LIFT OUT BATTERY TRAY 30 Spare Parts REF 1 PART NO 2360320012 2382320009 2360320014 2360320015 2360320024 2360320025 2803000003 2366320015 2365000001 2365000002 2367320002 2367320001 2367320008 2367320007 DESCRIPTION STEEL CAB SEATBACK CAB RIGHT DOOR LEFT DOOR RIGHT DOOR REAR PASSENGERS LEFT DOOR REAR PASSENGERS PADDLE LATCH DOOR LATCH RIGHT HINGES KIT LEFT HINGES KIT RIGHT DOOR GLASS LEFT DOOR GLASS CAB RIGHT DOOR GLASS REAR PASS LEFT DOOR GLASS REAR PASS 4 or 6 passengers option 31 PART NO 2801000002 2802000001 2801000001 2399000014 3113000001 2800000002 2800000001 2366320001 2366320002 2366320003 2367300001 2367300002 DESCRIPTION REAR VIEW MIRROR TRIM DOOR SIDE MIRROR SIDE MIRROR BRACKET WIPER MOTOR WIPER ARM DOOR HANDLE DOOR HANDLE BAR DOOR LEVER REAR GLASS WINDSHIELD Spare Parts DIFFERENTIAL POWER DANA CORPORATION SPICER OUTDOOR EQUIPMENT COMPONENTS DIVISION d gt AN A VS 4 INCLUDED IN A KIT SEE PARTS LIST 32 Spare Parts
27. NUT 1 2 NF BUSHING E 320 322 330 360 amp 480 STANDARD E 500 amp 660 AND OPTIONAL E 320 322 330 360 amp 480 40 OSAH3OWVHO CRL X3d3S ONIMVHG NONOVO f uoHinv 81 20 8002 LO NOISYJA XIJIS NIVA uu HLIM 5 93MLON CIRCUIT PRINCIPAL SEPEX 2 ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT DIAGRAMME ELECTRIQUE Spare Parts IIT BLK DC DC ali x x 3178 199VM18 33 03 41 39 940 SLS 95 10 65 uio ASA WMLTSETLZTHZ 90 90 ON 32 SNIMVHG f NOHinv 90 0 9002 LO NOISYSA 1 33 90 90 ON SOSS NMLTISFILZIHZ Lo3arens 334 LON 2118 Seuossoooe uo Buipuedep 10 AZI Jeuye si 85 9 eu p JOU SI uondo usum sod eAnisod Alapeq jsod slelpeuuelul ue je pejoeuuoo si punoJB seuos
28. O 20 0 20 M1 BRAKE RATE MODE 1 BRAKING RATE IN SEC 2 BDI LOCKOUT BDI LOCKOUT ON OR OFF OFF M2 BRAKE RATE MODE 2 BRAKING RATE IN SEC 2 BDI DISABLE BDI DISABLE ON OF OFF OFF M3 BRAKE RATE MODE 3 BRAKING RATE IN SEC 2 ADJ HRS LOW ADJ HRS LOW 0 TO 99 0 M4 BRAKE RATE MODE 4 BRAKING RATE IN SEC 2 ADJ HRS MID ADJ HRS MID 0 TO 99 0 INT BRAKE RATE INT BRAKE RATE IN SEC 2 ADJ HRS HIGH ADJ HRS HIGH 0 TO 99 0 QUICK START QUICK START THROTTLE FACTOR 0 SET TOTAL HRS SET TOTAL HRS ON OR OFF OFF TAPER RATE Regen brak Decrease rate when apporch Ospd 1 32s 20 SET TRAC HRS SET TRAC HRS ON OR OFF OFF M1 MAX FWD SPD MODE 1 FWD SPEED AS PWM OUTPUT 40 HOURMETER TYPE HOURMETER TYPE ON OR OFF OFF M2 MAX FWD SPD MODE 2 MAX FWD SPEED AS 96 PWM OUTPUT 72 SRVC TOTAL HRS SRVC TOTAL HRS 0 0 TO 50 0 0 0 M3 MAX FWD SPD MODE 3 MAX FWD SPEED AS 96 PWM OUTPUT 86 SRVC TRAC HRS SRVC TRAC HRS 0 0 TO 50 0 0 0 M4 MAX FWD SPD MODE 4 FWD SPEED AS PNM OUTPUT 100 SRVC TOTAL SRVC TOTAL ON OR OFF OFF M1 MAX REV SPD MODE 1 MAX REV SPEED AS PWM OUTPUT 40 SRVC TRAC SRVC TRAC ON OR OFF OFF M2MAX REV SPD MODE 2 MAX REV SPEED AS PWM OUTPUT 40 DIS TOTAL HRS DIS TOTAL HRS 0 TO 250 0 M3 MAX REV SPD MODE 3 MAX REV SPEED AS PWM OUTPUT 40 DIS TRAC HRS DIS TRAC HRS 0 TO 250 0 M4 MAX REV SPD MODE 4 MAX REV SPEED AS PWM OUTPUT 40 TRAC FAULT SPD TRAC FAULT SPEED 0 TO 100 100 CREEP SPEED CREEP SPEED AS Yo PWM OUTPUT 0 BDI LIMIT SPD BDI LIMIT SPE
29. OR HOT 3 1 Field resistance gt motor hot setpoint When resistance setpoint N MOTOR WARM 3 1 Field resistance gt motor warm setpoint When resistance Fig 21 Curtis 840 Spyglass 3 LED 3 LED Spyglass The hourmeter LED lights when the LCD and GLED model is displaying hourmeter data The BDI LED lights when the LCD is displaying BDI It flashes when BDI drops to lt 10 The Fault LED flashes to indicate an active fault and the fault code appears on the LCD The word SERVICE is displayed at key on if either service timer has expired 8 character LCD display NE Hourmeter LED green 2 Q _ Fault LED red BDI LED yellow 6 LED Spyglass The three green BDI LEDs function as a bargraph showing BDI between 52 and 100 Yellow LED 36 51 BDI Red LED steady 20 35 BDI Fault LED red 7 Red LED flashing 0 19 8 character LCD display The Fault LED flashes to indicate an active fault and the fault code appears on 0 1 the LED yellow 99990 green The word SERVICE is displayed at key on if either service timer has expired 0 100 LEDs Curtis 1243cen2 Manual 73 226 7 DIAGNOSTICS amp TROUBLESHOOTING STATUS LED DIAGNOSTICS A Status LED is built into the 1243GEN2 controller It is visible through window in the label on top of the controller This Status LED displays fault cod
30. PLUG PLUG ASSY DC 175 AMP ANDERSON PLUG FUSE ASSEMBLY 49 Spare Parts 100 125 200 225 VAC INPUT BUILT IN PORTABLE CHARGER MODEL 16360 40 AC VOLTAGE POWER SELECTOR SWITCH SWITCH SHOWN IN 100 125 VOLT POSITION PART NO 209525 163655 163695 209195 209485 214755 192335 020285 038945 209165 209245 209145 209265 219125 214085 053225 150295 209175 186965 140925 DC EUSE SCR OUTPUT WHITE gt BLACK lod e y 7 T t MN dime c 10 BLACK men H e eae YELLOW TRANSFORMER BROWN ELECTRONIC 7 TIMER 8 BLUE NATURAL BLUE L2115849 Parts list for MODEL 16360 40 TYPE 36EL20 SET 100 125 or 200 250 VAC 50 60 Hz QTY DESCRIPTION CASE ASSEMBLY TRANSFORMER ASSEMBLY AMMETER HEATSINK ASSEMBLY W SCR SCR ASSEMBLY ELECTRONIC TIMER ASSEMBLY CONTROL CABLE ASSEMBLY BUSHING INSULATOR 7W 2 FOR DC CORDSET BUSHING INSULATOR 7K 2 FOR AC CORDSET CORDSET AC 16 3 80 MOLDED PLUG CORDSET DC 12 2 108 SB 50 PLUG GRAY CORDSET DC 12 2 108 SB 50 PLUG RED CORDSET DC 12 2 108 SB 175 PLUG RED CORDSET DC 12 2 108 SB 175 PLUG GRAY CORDSET DC 12 2 108 NO PLUG FUSEHOLDER FUSE 12 AMP MDA 12 SWITCH ASSEMBLY SHUNT ELECTRONIC 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 CIRCUIT BREAKER 40 AMP 50 Spare Parts NO DELTA PART NO 3102240002 3102240003 3102240004 3102240005 3102302001 3102302
31. QUENCING DELAY IN SEC 1 M3 DRIVE MODE 3 DRIVE CURRENT LIMIT IN AMPS 250 MAIN CONT INTR MAIN CONTACTOR INTERLOCK ON OR OFF ON M4 DRIVE C L MODE 4 DRIVE CURRENT LIMIT IN AMPS 250 MAIN OPEN DELAY MAIN CONTACTOR DROPOUT DELAY IN SEC 1 M1 BRAKE C L MODE 1 BRAKING CURRENT LIMIT IN AMPS 100 CONT DIAG CONT DIAG ON OR OFF ON M2 BRAKE C L MODE 2 BRAKING CURRENT LIMIT IN AMPS 100 AUX TYPE AUXILIARY TYPE 0 TO 5 0 M3 BRAKE C L MODE 3 BRAKING CURRENT LIMIT IN AMPS 100 AUX DELAY AUXILIARY DRIVER DROPOUT DELAY IN SEC 0 0 M4 BRAKE C L MODE 4 BRAKING CURRENT LIMIT IN AMPS 100 EMR REV C L EMERGENCY REVERSE CURRENT LIMIT IN AMPS 50 0 M1 ACCEL RATE MODE 1 ACCELERATION RATE IN SEC 3 EMR REV CHECK EMERGENCY REV WIRING CHECK ON OR OFF OFF M2ACCEL RATE MODE 2 ACCELERATION RATE IN SEC 3 EMR DIR INTR EMR DIR INTR ON OR OFF OFF M3 ACCEL RATE MODE 3 ACCELERATION RATE IN SEC 3 VARIABLE BRAKE VARIABLE BRAKE ON OR OFF OFF M4 ACCEL RATE MODE 4 ACCELERATION RATE IN SEC 3 ANTI TIEDOWN ANTI TIEDOWN ON OR OFF OFF M1 DECEL RATE MODE 1 DECELERATION RATE IN SEC 3 4 POT LOW FAULT POT LOW FAULT ON OR OFF ON M2 DECEL RATE MODE 2 DECELERATION RATE IN SEC 3 4 FULL VOLTS FULL VOLTS 174 TO 211 204 M3 DECEL RATE MODE 3 DECELERATION RATE IN SEC 3 4 EMPTY VOLTS EMPTY VOLTS 0 TO 211 174 M4 DECEL RATE MODE 4 DECELERATION RATE IN SEC 3 4 RESET VOLTS RESET VOLTS 174 TO 300 210 THROTTLE DECEL THROTTLE DECEL IN SEC 0 3 BATTERY ADJUST BATTERY ADJUST 0 1 T
32. RENTIAL Before adding oil check oil seals for leaks TIGHTEN NUTS BOLTS electric terminals drive steering brakes suspension body REPLACE DIFFERENTIAL OIL SAE 30 x CLEAN AND RE PACK FRONT HUBS x SERVICE DIFFERENTIAL replace the three oil seals po wheel bearings oil SAE 30 11 Maintenance ACCELERATOR GEAR Remove the cover Backlash between gears must be reduced to a minimum by sliding holder use locktite 262 to lock the three screws When the plastic gear is fully depressed a small backlash must remain between the gears When plastic gear is released its rear portion must not exceed the pedal case MICRO SWITCH The micro switch must deactivate the on off solenoid when the accelerator is released turn the adjusting screw shown on figure below to adjust the micro switch height POT Remove the terminals 2 and 3 on to measure resistance signal When the micro switch is activated the signal must be less than 50 ohms When the front portion of the pedal is fully depressed the signal must be more than 4600 ohms modify the resistance turn the adjusting screw to change the micro switch height see figure below Proceed with the same verifications after the accelerator cover is on and then connect terminals 2 and 3 POTENTIOMETER AUXILIARY SWITCH IS WIRED N O WITH BLUE LEAD TO COM amp ORANGE LEAD TO N O CIRCU
33. RUCTIONS SAFETY WARNINGS FOR OPERATORS OPERATING INSTRUCTIONS MAINTENANCE SAFETY WARNINGS FOR SERVICE TECHNICIANS DECALS AND LABELS PERIODIC MAINTENANCE CHECKLIST ACCELERATOR HYDRAULIC amp PARKING BRAKES FRONT AXLE AND STEERING BATTERY MAINTENANCE BATTERY CHARGER ELECTRICAL TROUBLESHOOTING CURTIS SPEED CONTROLLER WIRING STANDARD CONFIGURATION DIAGNOSTICS AND TROUBLESHOOTING TROUBLESHOOTING CHART LED DIAGNOSTICS PROGRAMMING PARAMETERS 300 E 302 E 322 amp E 330 SPARE PARTS BODY CAB DIFFERENTIAL HYDRAULIC DRUM BRAKES HYDRAULIC BRAKE CONTROLS FRONT ASSEMBLY MOTOR AND DRIVE REAR SUSPENSION AND BRAKE ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT ACCESSORIES NO DC DC CONVERTER ACCESSORIES DC DC CONVERTER OPTIONS BATTERY CONFIGURATIONS 36V BUILT IN CHARGER MODEL 6430 00 PORTABLE CHARGER MODEL 07710 02 BUILT IN PORTABLE 40A CHARGER BUILT IN PORTABLE CHARGER MODEL 16360 40 DELTA Q HF CHARGER MOTREC ILLUSTRATED ACCESSORIES BATTERY DISCHARGE INDICATOR HOBBS ADDENDUM CURTIS FOOT PEDAL co A gp 10 12 13 14 15 17 18 21 23 24 25 27 28 29 30 31 32 34 35 36 38 39 41 42 43 44 46 47 48 49 50 51 54 56 57 58 Instructions INSTRUCTIONS Instructions SAFETY WARNINGS FOR OPERATORS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAY RESULT IN SEVERE INJURY e 15 the responsibility of the owner of this vehicle to train operators to ensure that the
34. adequate capacity identify and disconnect battery leads Don t connect the charger CHECK PERFORM HOURS 20 50 200 1000 2000 MECHANICAL DAMAGE OIL LEAKS X j REVERSE ALARM DEADMAN SWITCH X STATIC STRAP min 2 contact with ground HE j E E j y TIRE PRESSURE pressure rating on tire x CHECK FILL BATTERIES add distilled water to cover plates Fill to recommended level after batteries have been E 1 1 1 1 fully charged WARNING DECALS amp MARKINGS J x j EE Rated CABLE PROTECTORS SEALED MOTOR SEALED CONTROL STATE SEA x L MASTER CYLINDER FLUID DOT3 po BRAKE PEDAL TRAVEL 2 50 mm maximum travel STEERING FOR PLAY PARKING BRAKE LEVER ee Siwa BELTS AND PULLEYS 10 lbs 5kg force for 1 8 3mm deflexion pulleys alignment see procedure CLEAN TIGHTEN WIRE TERMINALS WASH BATTERY TOP WITH WATER II MOTOR BRUSHES FOR WEAR oema ACCELERATOR ADJUSTMENT 1 8 3 mm travel to activate micro switch 0 to 50 ohms when micro switch activated 4500 to 5500 ohms with pedal down HYDR BRAKE LINES FOR LEAK STEERING ASSEMBLY as instructed u BRAKE MECHANICAL LINKAGES for wear amp play BRAKE LININGS FOR WEAR 1 16 2 mm minimum lining thickness 6 mm minimum thickness for brake pulley lining mama o x column ball joints and kingpins OIL SAE 30 LEVEL IN DIFFE
35. ation will be allowed for delays To initiate warranty coverage on any MOTREC vehicle the Dealer must complete and return the Sales Installation Report to MOTREC within 30 days after delivery to the Original Retail Purchaser or within 90 days after the delivery date to the Dealer which ever occurs first Failure to follow these procedures will result in considering the warranty coverage effective as of the shipment date from the factory The defective vehicle must be returned at the Owner s expense to an authorised MOTREC Dealer within 30 days after failure The Owner will not be charged for parts and labour required for warranty repairs which must be performed by an authorised MOTREC Dealer only The vehicle will be returned at the owner s expense The Warranty Claim Forms must be completed and returned with the defective part s to MOTREC within 30 days after repair was done No compensation will be allowed for damages caused by vehicle downtime It is the responsibility of the owner of the vehicle to make sure that the driver is properly trained and instructed in the safety features and operation of the vehicle including vehicle stability as required by OSHA and ANSI B56 Operators shall read understand and follow the safety and operating instructions in MOTREC Manual before driving the vehicle Operators shall not be permitted to drive the vehicle unless a complete and adequate training has been provided Driving a vehicle constitutes a haza
36. b on the brake lever until a force of 75 Lbs or 34 kg is required on the handle to set the parking brake BRAKE PEDAL If the brake pedal becomes soft or spongy air may have entered the hydraulic system and the brake system has to be bled 1 fill the master cylinder with brake fluid DOT 3 2 bleed front callipers one at a time by having someone applying a steady pressure on the brake pedal and close the bleeder before allowing the brake pedal to return to up position fill the master cylinder with brake fluid DOT 3 bleed rear wheel brakes one at a time following the same procedure fill the master cylinder with brake fluid DOT 3 clean every fitting and line remove traces of oil apply a continuous pressure on the brake pedal for about five minutes Finally inspect brake lines and fittings for leaks gov Ov eg 13 Maintenance FRONT AXLE AND STEERING CAUTION Before maintenance turn off all switches set to neutral set parking brake remove the key and raise the front end of the vehicle supporting it with two jack stands of adequate capacity STEERING INSPECTION Check tire inflation pressure suspension components tie rods straightness tie rod ends play wear play wear in wheel bearings kingpins and bushings REPLACING amp ADJUSTING THE STEERING GEAR Remove the pitman arm steering box makes 6 5 turns center the steering gear 3 25 turns from either side
37. ck main contactor or solenoid Check voltage across power terminals if not check circuit breaker or replace the solenoid Turn to on the key switch and activate the seat switch Check voltage across the coil terminals if not check wiring and interlock switches Check resistance across power terminals if not 0 ohms replace the solenoid Check circuit breaker and SEPEX DIODE Before replacing the circuit breaker check for shorts in the power circuit and check the SEPEX diode in the power circuit using a diode tester If no such instrument is at hand use an ohmmeter the reading should be weak in one direction and strong in the other way Check the resistance across the circuit breaker If not 0 ohms replace the circuit breaker Check PMC First disconnect battery B and B then PMC B and M Check the internal diode between B and M terminals using a diode tester If no such instrument is at hand use an ohmmeter the reading should be weak in one direction and strong in the other way If the internal diode is defective the PMC must be replaced Check the Motor First disconnect battery and B disconnect power terminals and check the motor armature and field for opens 20 Curtis Speed Controller CURTIS SPEED CONTROLLER 21 MANUAL 233 1243 Generation 2 MultiMode MOTOR CONTROLLER 2002 CURTIS INSTRUMENTS INC DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U S
38. ck voltage between output terminal on the key switch and the terminal on the battery gage if not B replace the key switch Check voltage across DC DC converter output terminals if not 12 Volt replace the converter Depress the accessory switch check voltage across accessory terminals If not 12 Volt replace the switch If 12 Volt replace the accessory FORWARD ONLY On a SEPEX motor control check the reverse signal input on the controller On a series wound motor control a bad reverse contactor is the most probable cause of the problem Switch to reverse and check voltage on the reverse control wire If not B replace the F R switch If B turn off the key switch disconnect batteries disconnect power terminals on the F R contactors check the resistance across N C power terminals of the reverse contactor If not 0 ohm change the reverse contactor If 0 ohms switch to forward and check the resistance across the forward N O power terminals If not 0 ohms change the forward contactor 18 Maintenance REVERSE ONLY On a SEPEX motor control check the forward signal input on the controller On a series wound motor control a bad forward contactor is the most probable cause of the problem Switch to forward and check the voltage on the forward control wire If not B replace the F R switch If turn off the key switch disconnect batteries disconnect power terminals on the F R contactors check the resista
39. e troubleshooting chart Table 7 for suggestions about possible causes of the various faults Operational faults such as a fault in SRO sequencing are cleared by cycling the interlock switch or keyswitch Curtis 1243e n2 Manual 27 74 Curtis Speed Controller PROGRAMMING PARAMETERS E 300 E 302 E 322 amp E 330 WARNING The owner of this vehicle shall ensure that the service technicians are qualified properly trained and obey the safety rules and guidelines in OSHA and ANSI B56 regulations and in this manual Before installing and or programming the PMC park the vehicle on a flat level surface lift the wheels off the ground and secure with jack stands of adequate capacity Don t connect charger Programmable controllers must be programmed using the parameter settings in this service manual before connecting the motor to avoid sudden vehicle movement and accident Do not try to increase motor speed by changing parameter settings in the speed controller it can cause accident and severe damage to the motor VOLTAGE NOMINAL BATTERY VOLTAGE IN VOLTS 3 HPD HIGH PEDAL DISABLE HPD TYPE 1 M1 DRIVE C L MODE 1 DRIVE CURRENT LIMIT IN AMPS 250 SRO STATIC RETURN TO OFF SRO TYPE 1 M2 DRIVE C L MODE 2 DRIVE CURRENT LIMIT IN AMPS 250 SEQUENCING DLY SE
40. els 912 xx0x will flash the 100 LED When Models 912 xx0x 100 LED or Models 912 xx1x single LED is continuously GREEN the batteries are completely charged The charger may now be unplugged from AC power always pull on plug and not cord to reduce risk of damage to the cord If left plugged in the charger will automatically restart a complete charge cycle if the battery pack voltage drops below a minimum voltage or 30 days has elapsed If a fault occurred anytime during charging a fault indication is given by flashing RED with a code corresponding to the error There are several possible conditions that generate errors Sorne errors are serious and require human intervention to first resolve the problem and then to reset the charger by interrupting AC power for at least 15 seconds Others may be simply transient and will automatically recover when the fault condition is eliminated To indicate which error occurred a fault indication will flash RED a number of times pause and then repeat 1 FLASH Battery Voltage High auto recover 2 FLASH Battery Voltage Low auto recover FLASH Charge Timeout the charge did not complete in the allowed time This may indicate a problem with the battery pack voltage not attaining the required level or that the charger output was reduced due to high ambient temperatures 4 FLASH Check Battery the battery pack could not be trickle charged up to the minimum level required for the charge to be started T
41. er the bulk charging constant current stage Models 912 will display the current to the battery on the bargraph and Model 912 xx1x will flash its LED GREEN off more than on to indicate 8096 charge status The length of charge time will vary by how large and how depleted the battery pack is the input voltage the higher the better and ambient temperatures the lower the better If the input AC voltage is low below 104VAC then the charging power will be reduced to avoid high input currents Models 912 AC LED and Models 912 1 single LED both flash YELLOW If the ambient temperature is too high then the charging power will also be reduced to maintain a maximum internal temperature Models 912 xx0x bargraph flashes and Models 912 xx1x single LED flashes YELLOW When the battery is at approximately 80 state of charge the bulk stage has completed and an gt 80 charge indication is given Models 912 turn on the 80 LED and Models 912 xx1x will fiash its LED GREEN on more than off In the next phase known as the absorption or constant voltage phase the last 20 of charge is then returned to the battery The charging could be terminated at this point if the vehicle requires immediate usage however it is highly recommended to wait until 10096 charge indication is given to ensure maximum battery capacity and life A low current finish charae phase is next applied to return and maintain maximum battery capacity Mod
42. erver ces instructions Ce manuel contient des instructions importantes concernant la s curit et le fonctionnement Information de S curit de la Batterie Electrical Safety Information Danger Risk of electric shock Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances A grounded outlet is required to reduce risk of electric shock do not use ground adapters or modify plug Do not touch uninsulated portion of output connector or uninsulated battery terminal Disconnect the AC supply before making or breaking the connections to the battery while charging Do not open or disassemble charger Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow been dropped or otherwise damaged in any way refer all repair work to qualified personnel Not for use by children Attention utiliser seulement sur les batteries 72V avec un algorithme appropri au type sp cifique de batterie voire le manuel D autres types de batteries pourraient clater et causer des blessures ou dommages Les batteries peuvent produire des gaz explosives en service normal Ne jamais fumer pr s de la batterie et viter toute tincelle ou flame nue proximit de ces derniers Fournisser la bonne ventilation lors du chargement Ne jamais charger une batterie gel e Prendre connaissance des mesures de pr caution sp
43. es when there is a problem with the controller or with the inputs to the controller During normal operation with no faults present the Status LED flashes steadily on and off If the controller detects a fault a 2 digit fault identification code is flashed continuously until the fault is corrected For example code 3 2 main contactor welded appears as uu uu uu 3 2 3 2 3 2 codes are listed in Table 8 Table8 STATUS LED FAULT CODES LED CODES EXPLANATION LED off no power or defective controller solid on controller or microprocessor fault 0 1 ma controller operational no faults 1 1 current sensor error 1 2 a an hardware failsafe fault L3 a M fault or motor output short 1 4 a KODA static return to off SRO 251 oo throttle wiper high 2 2 emergency reverse circuit check fault 2 3 uon high pedal disable HPD or expired timer 2 4 oo aona throttle wiper low 3 1 ooo a contactor driver overcurrent or field winding short 22 non nu main contactor welded 2 9 nun ODA field winding open 3 4 ooo missing contactor 4 1 n low battery voltage 4 2 nu overvoltage 4 3 ooo thermal cutback due to over under temp 4 4 adan anti tiedown fault or overheated motor SE J Note Only one fault is indicated at a time and faults are not queued up Refer to th
44. g the vehicle could damage the charger and produce a spark battery explosion and acid splashing e Use another driver to steer this vehicle while it is towed Be sure the driver uses brakes when you slow or stop the towing vehicle Do not exceed 5 MPH or carry any passenger while towing this vehicle Instructions OPERATING INSTRUCTIONS It is the responsibility of the owner of this vehicle to ensure that the operator understands the operating characteristics of this vehicle and obeys the safety instructions in this manual and ANSI ITSDF B56 8 amp 9 Standards Do not drive this vehicle unless you are a certified operator as required by OSHA BEFORE TURNING ON KEYSWITCH Set to neutral set parking brake check for visible damage check brake pedal AFTER TURNING ON KEYSWITCH Check safety devices seat switch reverse alarm motion beeper strobe light and all other safety devices BATTERIES Never open the battery compartment unless you have received proper training for battery maintenance Batteries emit explosive hydrogen gas that can be ignited by a spark or loose terminal Battery acid causes severe damage to eyes or skin Flush the contaminated area immediately with water Park the vehicle in a well ventilated area for battery charging Most battery chargers come with an electronic control that starts when the charger is plugged and stop when the battery is fully charged To interrupt the charging cycle disconnect the AC p
45. he key switch is ON and seat switch is activated PMC may also have an SRO safety feature that prevents the vehicle from moving if the F R switch is activated before turning on the key switch and activating the seat switch The vehicle stops on a steep and long ramp or while towing a heavy load the circuit breaker has open to prevent motor overheating and will reset automatically after one minute The PMC is also equipped with an internal thermal protection that cutback the current until the PMC has cooled down 19 Maintenance NO MOTION Make sure that the PMC surface is clean and dry check the terminal areas Dust Particles or acid contamination can create current leaks and cause a PMC malfunction Check F R switch Turn on the key switch and set to forward Check voltage between the forward terminal and the terminal on the battery gage check voltage between the reverse terminal and the terminal on the battery gage if both B replace the F R switch Check switches and wiring Disconnect control terminals on the PMC and check all control signals If a switch pin does not read B check wiring or replace the switch Check potentiometer Turn the key switch to OFF disconnect potentiometer terminals Check the resistance across terminals if not within the recommended limits adjust or replace the potentiometer Check for shorts between potentiometer wires and vehicle frame resistance should read at least 1 megohm Che
46. his may indicate that one or more cells in the battery pack are shorted or damaged 5 FLASH Over Temperature auto recover Charger has shutdown due to high Internal temperature which typically indicates there is not sufficient airflow for cooling see Installation Instructions 1 Charger will restart and charge to completion if temperature comes within accepted limits 6 FLASH QuiQ Fault an internal fault has been detected If Fault 6 is again displayed after interrupting AC power for at least 15 seconds the charger must be brought to a qualified service depot Maintenance Instructions 1 A 3 For flooded lead acid batteries regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer Follow the maintenance and safety instructions recommended by the battery manufacturer Make sure charger connections to battery terminals are tight and clean Do not expose charger to oil dirt mud or to direct heavy water spraying when cleaning vehicle See flip side for Product Specifications and Installation Instructions for qualified personnel E 52 Spare Parts Specifications DC Output see Operating Instructions Mechanical Model 912 24xx 36xx ANT Voltage nom V
47. l Can be caused by a transformer failure 17 Maintenance ELECTRICAL TROUBLESHOOTING WARNING Maintenance work must be performed by trained service technicians only It is the responsibility of the owner of this vehicle to ensure that the services technicians are properly trained understand and obey the safety rules and guidelines ANSI B56 service technicians must read and understand the maintenance warning section in this manual WARNING Before any maintenance work park the vehicle on a flat level surface turn off all switches remove the key lift the wheels off the ground secure with jack stands of adequate capacity disconnect charger Always wear safety glasses Batteries emit highly explosive gases that can be ignited by a spark Before disconnecting a high current terminal turn off all switches disconnect battery charger disconnect batteries Keep clear from moving parts such as tires sheaves and motor PMC SELF DIAGNOSTIC If your PMC comes with a status led use the flashing code to help troubleshooting BATTERY VOLTAGE Make sure batteries are securely connected Measure voltage between and terminals We will call this value or full battery voltage ACCESSORIES NOT WORKING Check the fuses on the batteries and the DC DC converter Check voltage across and terminals on the battery gage if not check wiring Turn the key switch ON che
48. lug do not disconnect the DC plug BATTERY DISCHARGE INDICATOR The green light moves from right to left as batteries are being discharged When the green light is at the last position on the left the batteries must be recharged A flashing light warns the operator that further discharge will damage batteries See HOBBS indicator instructions EMERGENCY SAFETY DEVICE The emergency push button or battery disconnect handle when present should only be used in case of emergency Use the key switch for normal ON OFF control KEYSWITCH Depress brake pedal and turn the key switch clockwise for on position Always turn off all switches set the F R selector to neutral set the parking brake remove the key before leaving the vehicle HORN Depress the horn button on the steering column or handle bar F R SWITCH Three positions with neutral at center Depress the front part of the rocker switch for forward direction Depress the rear part of the rocker switch for reverse direction Always set switch to neutral turn off all switches set the parking brake remove the key before leaving the vehicle ACCELERATOR PEDAL It is designed for right foot operation only and controls the speed of the vehicle Apply slowly FOOT BRAKE PEDAL It is designed for right foot operation only The brake force is proportional to the pressure on the pedal PARKING BRAKE Pull handbrake lever to apply Never park the vehicle on an incline Always turn off
49. nce across N C power terminals of the forward contactor If not 0 ohm change the forward contactor If 0 ohms switch to reverse and check the resistance across the reverse N O power terminals If not 0 ohms change the reverse contactor TRAVEL AT REDUCED SPEED Check batteries Turn off all switches and disconnect charger Wear face shield and gloves Do not disturb any battery connection to avoid sparks Check the specific gravity of each cell Cold batteries highly discharged batteries or dead cells are the most frequent causes of reduced travel speed Check potentiometer Turn off the key switch disconnect potentiometer terminals Check the resistance between terminals Other causes of lower speed dragging brakes cold temperature higher differential oil viscosity INTERMITTENT OPERATION A bad potentiometer is the most probable cause of the following acceleration is not constant maximum speed is erratic sudden stop after a bump or shock erratic starts requiring several pedal cycles A bad F R contactor is also a probable cause of the following sudden stop after a bump or shock would not start to move at times Erratic starts could also be the cause of a misadjusted potentiometer or micro switch the pot signal must be less than 50 ohms when the micro switch turns on PMC has an HPD safety feature that prevents the vehicle from moving if the accelerator pedal is depressed before t
50. nch technique when disconnecting or tightening terminals on the battery and the speed controller to avoid cracking the terminal or battery post welds Before cleaning or replacing a battery charger speed controller contactor relay diode or any other component in the power circuit always disconnect the charger turn off all switches remove the key wear a face shield and gloves identify battery polarity and disconnect battery leads discharge the capacitor in the controller with a 10 ohms 25 W resistor for a few seconds across B and B After cleaning the power must not be reapplied until terminal areas are thoroughly dry On EE Rated vehicles make sure that the control box is sealed the static strap makes good contact with the ground the motor is sealed by bands the cable protectors are properly installed Keep cables and wires clear from mechanical and rubbing action Make sure that cable insulation is free from cutting or visible damage Make sure that EE Rated cable protectors are properly installed Before replacing a fuse or circuit breaker identify the cause of failure and repair Programmable controllers must be programmed using the parameter settings in this service manual before connecting the motor to avoid sudden vehicle movement and accident Maintenance Do not try to increase motor speed by changing parameter settings in the speed controller it can cause accident and severe damage to the motor SEPEX speed co
51. nd the last Algorithm Table 1 moves back to the first Algorithm After desired Algorithm is displayed touch the charger connector to the battery positive until the output relay is heard to click 10 seconds algorithm is now in permanent memory c Remove AC power from the charger and reconnect the charger positive connector to the battery pack It is highly recommended to check a newly changed algorithm by repeating step 4 above 3t Concorde 2xxAh AGM Crown CR325 dv dt Deka 8GGC2 Gel Concorde 1xxAh AGM Trojan J305 dV dt DEKA 8G31 Gel Trojan 30XHS Product warranty is two years please contact dealer of original equipment for warranty service Note This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures Aug 2006 9 Delta Q Technologies Corp All rights reserved PN 710 00xx Rev 1 V1 16 S3 Spare Parts MOTREC ILLUSTRATED ACCESSORIES Strobelight polemount Amber 12 80V 3116000001 Red 12 80V 2469001 Blue 12 80V 3690008 Strobelight cab mount Amber 12 48V 3116250001 Red 12 48V 3069026 Blue 12 48V 3069014 Amber 72 80V 3116720001 Red 72 80V 3116720002 Blue 72 80V 3116720003 a Amber turn lamp 12V 3069020 Bulb 12V 3069021 Multi LED amber turn lamp Round Light 3111000010 Grommet 3111000008 Plug 3111000009 Red Tail Brake light Grommet
52. ntrols are protected by a diode in the power circuit to filter inductive loads in the event of a sudden power interrupt Some speed controllers require a diode to filter inductive loads on the KSI input Removing the diodes will cause the speed control failure Before resuming maintenance operations inspect safety warnings stickers and replace any if damage is found and part of the text can t be read Check decals and labels see DECAL AND LABELS page Maintenance DECALS AND LABELS CAUTION The images included in this section depict the decals markings installed on the vehicle It is of the utmost importance that theses decals markings remain unaltered and readable Else the sticker or the part baring the marking has to be replaced Dashboard security warning label General security warning label 5100000002 5100000001 Operation of this vehicle is restricted to authorized persons only Read operator s instructions in owner s manual prior to driving Operation of this vehicle i Read operator s tio ner s manual prior to driving Do not operate on roads public and unauthorized areas Never n battery compartment Never open motor compartment When an emergency push button is E m v 1d moving or lifting parts gt 3 ass capacity installed this label is required located on ramps in tu gt cargo Before turning on key switch and while moving be sure that under push button 31
53. ograph wiper arm 246233A Pantograph wiper blade 246233 8 Cab heater 12V 3103300001 36V 3669008 48V 4869020 12V Domelight 3669006 12V Fan 3669013 Headlamp 12V 3111300001 Bulb 12V 3111300002 Red Pilot light 12V 246212 Bulb 12V 246212B 2 Back up alarm or Motion beeper 12 48V 3100000001 72 80V 3105720001 12 24V Adjustable 3100000002 SS Spare Parts BATTERY DISCHARGE INDICATOR HOBBS This indicator monitors the residual capacity of batteries operating hours Status of service down counter The residual capacity of the battery is monitored via an 8 LED bar display When the left red LED lights the batteries must be charged to avoid damage The LED display starts flashing as a pre warning signal The lower voltage limit is adjustable via potentiometer M on the rear A c G J 1 68 In order to activate a new adjustment the unit has to be reset 2 35V cell reset voltage with battery remaining in vehicle 2 09V cell reset voltage after battery has been disconnected To maintain a good battery performance it is recommended to limit the discharging to 8096 of the battery capacity The recommended setting for 6V batteries is F and the recommended setting for an industrial battery is K An internal relay can prevent overdischarging and damaging the batteries The relay can be wired to cut off the reverse
54. rd The driver is responsible for the control of the vehicle while driving and must always evaluate and care for all peculiar situations that he or she may meet while driving The driver assumes the inherent hazards related to this activity The vehicle is designed for off road use only MOTREC disclaims any liability for incidental or consequential damages to include but not be limited to personal injury or property damage arising from vehicle misuse lack of maintenance or any defect in the vehicle It is the responsibility of the Owner of the vehicle to make sure that the service technicians are properly trained as required by OSHA and ANSI B56 Service technicians shall read understand and follow instructions in the MOTREC manual before servicing the vehicle Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect the vehicle MOTREC prohibits and disclaims responsibility for any vehicle modification altering the weight distribution and stability increasing the speed or affecting the safety of the vehicle Such modifications can cause serious personal injury or property damage for which MOTREC disclaims any responsibility For Owners that are located outside North America the warranty period starts the date of shipment from the factory and the defective parts must be returned at the Owner s expense to MOTREC prior to warranty repair 07 03 2008 Table of contents TABLE OF CONTENTS INST
55. roller 1 4 SRO 3 1 Improper seguence of KSI interlock Follow proper seguence and direction inputs adjust throttle if necessary 2 Interlock or direction switch circuit open adjust programmable 3 Seguencing delay too short parameters if necessary 4 Wrong SRO or throttle type selected 5 Misadjusted throttle pot 2 1 THROTTLE WIPER HI 1 1 Throttle input wire open or shorted to When Throttle Wiper High 2 Defective throttle pot input returns to valid range 3 Wrong throttle type selected 2 2 EMR REV WIRING 1 1 Emergency reverse wire or check wire Re apply emergency reverse open or cycle interlock 2 3 HPD 3 1 Improper sequence of KSI interlock Follow proper sequence and throttle inputs adjust throttle if necessary 2 Misadjusted throttle pot adjust programmable 3 Sequencing delay too short parameters if necessary 3 Wrong HPD or throttle type selected 5 Misadjusted throttle pot SRVC TOTAL 3 1 Total maintenance timer expired Reset with programmer SRVC TRAC 3 1 Traction maintenance timer expired Reset with programmer TOTAL DISABLED 3 1 Total disable timer expired Reset with programmer TRAC DISABLED 3 1 Traction disable timer expired Reset with programmer 24 THROTTLE WIPER LO 1 1 Throttle pot wire open shorted to B When Throttle Wiper Low 2 Wrong throttle type selected input returns to valid range 3 Defective throttle pot 3 1 FIELD SHORT 1 1 Main contactor coil shorted Check contac
56. seooV A 853 nans VC BLK RED RED BLK ca REDAWHT e gt sawa ACCESSORIES NO DC DC CONVERTER ACCESSOIRES SANS CONVERTISSEUR DC DC riga YEL 015 85 NUD L BLK e Je S LHM T WHT Spare Parts tud koci ao Ach r4 9 i E o 734 lva 42 OSA WMLISL1LZ1He 90 00 DOU NON9VeT 12 70 5002 10 NOISd3A W3LH3ANOO 99 90 SARIOSSIDIV OOV Loarans DSULOW ACCESSORIES DC DC CONVERTER ACCESSOIRES CONVERTISSEUR DC DC Spare Parts 23118 4 NYI BLK e 2119 953 vza LHM Manna SIS lt GRN Ki 8 8 BLK RED RED BLK ewe y D YIN L M QRN cas iks 43 NYO gt e D RED WHT N D WHT o f eis ors es RENT EE m N lt lt gt A a gt 21 i i i i i OSA MooTdalNI3
57. t outs for airflow is desirable Contact Delta Q for information on other mounting orientations As the charger may get hot in operation the charger must be installed such that risk of contact by people is reduced The charger s AC plug must be located at least 18 above the floor ground surface and the status display must be visible to the user 2 Mounting Procedure Mount the charger by the mounting plate using appropriate fasteners i e 1 4 or M6 with locking hardware For UL2202 compliance a 12AWG green bonding wire with ring terminals must be attached from the bonding stud located on the front of the charger identified by L to the vehicle frame The vehicle connection must be made using corrosion resistant hardware e g a 10 stainless steel machine screw with at least two threads of engagement and if required a paint piercing washer 3 DC Battery Connection Procedure The green wire outputs battery voltage when the charger is not plugged into AC to provide an interlock function see Fig 1 If used a user supplied 1A fast blow external fuse must be installed inline to prevent damage Shorting or drawing more than 1A may damage charger and void the warranty b Securely fasten the black ring terminal from the charger to the negative terminal NEG NEGATIVE of the battery pack c Check that the correct charge algorithm is being used refer to section 4 Securely fasten the red ring terminal to the positi
58. tor coil and 2 Field winding shorted to B or B field winding cycle KSI 3 Field resistance too low 3 2 MAIN CONT WELDED 1 1 Main contactor stuck closed Check wiring and contactor 2 Main contactor driver shorted cycle KSI 3 3 FIELD OPEN 1 1 Field winding connection open Check wiring and cycle KSI 2 Field winding open 3 4 MISSING CONTACTOR 1 1 Main contactor coil open Check wiring and cycle KSI 2 Main contactor missing Sa 3 Wire to main contactor open J Curtis 1243cEN2 Manual 25 72 7 DIAGNOSTICS amp TROUBLESHOOTING ES ES Table7 TROUBLESHOOTING CHART cont d LED PROGRAMMER FAULT CODE LCD DISPLAY CATEGORY POSSIBLE CAUSE FAULT CLEARANCE 4 1 LOW BATTERY VOLTAGE 2 1 Battery voltage undervoltage cutback When voltage rises above 2 Corroded battery terminal undervoltage cutoff point 3 Loose battery or controller terminal 42 OVERVOLTAGE 2 1 Battery voltage gt overvoltage shutdown When voltage falls below limit overvoltage cutoff point 2 Vehicle operating with charger attached 4 3 THERMAL CUTBACK 2 1 Temperature gt 85 C or lt 25 C Clears when heatsink 2 Excessive load on vehicle temperature returns to 3 Improper mounting of controller within acceptable range 4 4 ANTI TIEDOWN 3 1 Mode switches shorted to B4 Release Mode Select 1 2 Mode Select 1 tied down to select Mode 2 or Mode 4 permanently MOT
59. tteries Battery emits highly explosive gases do not produce sparks to avoid battery explosion and acid splashing Battery acid causes severe damage to eyes or skin Flush contaminated area immediately with water Use insulated tools to avoid sparks that can cause battery explosion and acid splashing Use two counteracting tools double wrench technique when disconnecting or tightening battery posts Before cleaning or replacing a battery discharge the capacitor in the controller with a 10 ohms 25 W resistor for a few seconds across B and B identify battery polarity and disconnect battery leads After cleaning the power must not be reapplied until terminal areas are thoroughly dry BATTERY LEADS AND CONNECTORS Check for loose connections damaged cables acid spill loose terminal posts quarterly BATTERY POST CORROSION If corrosion is present on battery posts remove the cable connectors use a wire brush to remove particles and then clean them with a cloth that has been moistened with ammonia ELECTROLYTE LEVEL Does not apply to sealed battery Disconnect battery connectors on roll out or lift out installations Make sure the battery roll out tray is provided with stops before rolling out Fill with distilled water Daily charged batteries normally require watering once a week Under watering leads to a shortened battery life Over watering leads to battery corrosion Be careful not to overfill
60. ty of each cell if a cell is shorted voltage drop may occur only when there 15 current 16 Maintenance BATTERY CHARGER WARNING Always unplug the AC and DC electrical cords before attempting any repairs to the charger CHARGER DOES NOT TURN ON Dc cord of portable chargers must be disconnected from batteries after every charge to restart Check dc fuse links Check battery voltage at the battery connector Check ac outlet and cordset Replace electronic control RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT REGISTER Check dc fuse links Check the continuity of the dc output cord ammeter diodes and all connections in the dc circuit Check diodes Check capacitor rapidely increasing resistance SINGLE CHARGER FUSE BLOWS Disconnect and check diodes BOTH FUSE LINKS BLOW Check the battery pack and battery connector polarity Disconnect and check diodes CHARGER OUTPUT IS LOW Disconnect and check diodes Can be caused by a transformer failure AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES Check the battery pack CHARGER DOES NOT TURN OFF Check specific gravity in each battery cell much as 16 hours may be required to properly charge heavely discharged new or cold batteries Replace electronic control AC LINE FUSE OR CIRCUIT BREAKER BLOWS Check ac cordset Check ac line fuse rating Replace electronic contro
61. ve terminal POS POSITIVE of the battery pack 1A Charger NC ERN Interlock Internal O B Output BLKANHT Figure 1 4 Check Change Charging Algorithm The charger comes pre loaded with algorithms for batteries as detailed in Table 1 If your specific battery model is not listed please contact Delta Q Each time AC power is applied with the battery pack NOT connected the charger enters an algorithm select display mode for approximately 11 seconds During this time the current Algorithm is indicated on the 80 LED Models 912 xx0x or on the single LED Models 912 xx1x A single digit Algorithm is indicated by the number of blinks separated by a pause A two digit Algorithm is indicated by the number of blinks for the first digit followed by a short pause then the number of blinks for the second digit followed by a longer pause To check change the charging algorithm a Disconnect the charger positive connector from battery pack Apply AC power and after the LED test the Algorithm will display for 11 seconds b To change algorithm touch positive connector during the 11 second display period to the battery pack s positive terminal for 3 seconds and then remove the Algorithm will advance after 3 seconds Repeat until desired Algorithm 3t is displayed A 30 second timeout is US Battery US2200 extended for every increment Trojan T 105 Incrementing beyo
62. xample the LED flashes 3 2 for a welded main contactor uu OOO uu OOO uu 2 32 3 2 and the corresponding Spyglass message is CODE 32 When a fault message is being displayed the red Fault LED labeled with a wrench symbol flashes to catch the operators attention The LCD also displays a warning when either service timer expires The service warning is not considered a fault and the red Fault LED does not flash The word SERVICE is displayed for about 20 seconds on each key on after the hourmeter is displayed The Spyglass is available in 3 LED and 6 LED models see Figure 21 Curtis 1243e n2 Manual 24 7 DIAGNOSTICS amp TROUBLESHOOTING N N Table7 TROUBLESHOOTING CHART LED PROGRAMMER FAULT CODE LCD DISPLAY CATEGORY POSSIBLE CAUSE FAULT CLEARANCE 01 NO KNOWN FAULTS 0 n a n a 1 1 CURRENT SHUNT FAULT 1 1 Abnormal vehicle operation causing Cycle KSI If problem high current spikes persists replace controller 2 Current sensor out of range 3 Controller failure 1 2 HW FAILSAFE 1 1 Noisy environment Cycle KSI If problem 2 Self test or watchdog fault persists replace controller 3 Controller failure 13 IM SHORTED 1 1 Internal or external short of M to B Check wiring cycle KSI 2 Incorrect motor wiring If problem persists 3 Controller failure replace cont
63. y understand the operating characteristics of this vehicle including training in vehicle stability and obey the following safety rules and guidelines Owner shall comply with OSHA and ANSI ITSDF 856 8 amp B56 9 Standards for vehicle use safety rules operator training and certification Do not drive this vehicle unless you are a qualified operator e Donotdrive this vehicle under the influence of drugs or alcohol Donotdrive this vehicle on public roads and highways This vehicle is designed to be driven in buildings e The electrical system of this vehicle will make sparks which can ignite inflammable materials Never use the vehicle in hazardous areas where there are inflammable materials explosive dust or fumes in the air e Have your vehicle inspected regularly by trained personnel and cease operation if a malfunction occurs e Donotopen battery compartment to prevent battery explosion acid splashing severe damage to eyes or skin e Do not open motor compartment Keep clear from moving rotating wheels sheaves etc or lifting parts e Never carry more passengers than number allowed for this vehicle Wait until all occupants are seated and holding on before moving Always keep all body parts inside vehicle Keep both hands on steering wheel Do not exceed the vehicle cargo load capacity and gross trailing weight capacity rated for flat hard even surface Different operating conditions such as loose terrain or ramps reduce vehicle

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