T-448HD ANCIEN a approuver
Contents
1. ACCELERATOR ADJUSTMENT X 1 8 3 mm travel to activate micro switch 0 to 50 ohms when micro switch activated 4500 to 5500 ohms with pedal down j _ HYDR BRAKE LINES FOR STEERING ASSEMBL Y as instructed for wear amp play 1 16 1 5 mm minimum lining thickness LUBRICATE brake pedal pivots steering T 31 column ball joints and kingpins OIL SAE 30 LEVEL IN DIFFERENTIAL Before adding oil check oil seals for leaks FRONT WHEEL BEARINGS PLAY S X ___ TIGHTEN NUTS BOLTS electric terminals X drive steering brakes suspension body REPLACE DIFFERENTIAL OIL SAE 30 XxX CLEAN AND RE PACK FRONT HUBS 2152 2212 ER SERVICE DIFFERENTIAL replace the three X oil seals 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 the 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 15 released turn the adjusting screw shown on figure below to adjust the micro switch height POT Remove the terminals 2 and 3 on P2. 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 Check main contactor or solenoid Check voltage across power terminals if not B 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 B 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 and B then and M Check the internal diode between and M terminals using a diode tester If no such instrument 15 at hand use an ohmmeter the reading should be weak in one direction and strong in the other way If the internal diode 1s defective the PMC must be replaced Check the Motor First disconnect battery and B disconnect power terminal
3. 79 Curtis Speed Controller PROGRAMMING PARAMETERS 480 T 44SHD WARNING The owner of this vehicle shall ensure that the service technicians are qualified properly trained and obey the safety rules and guidelines in 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 THRO DEADBAND Thr Neutral deadband 96 of 5kohms pot THROTTLE MAX Thr Input req d for 100 5kohm pot e MODE 3 THROT BRAKING AS OF BRAKE 100 RESTRAINT M4 THRT BRK 96 MODE 4 THROT BRAKING AS OF BRAKE C L 100 LOAD COMP M1 ACCEL RATE HIGH PEDAL DISABLE HPD TYPE TAPER RATE Decrease rate when apporch Ospd 32 M1 MAX SPEED MODE 1 MAX SPEED AS PWM OUTPUT 40 M2 MAX SPEED MODE 2 MAX SPEED AS PWM OUTPUT MAX SPEED MODE 3 MAX SPEED AS PWM OUTPUT 40 M4 MAX SPEED MODE 4 MAX SPEED AS PWM OUTPUT 0 O D D Ojo SEQUENCING DLY SEQUENCING DELAY IN
4. Make sure the battery roll out tray 1s 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 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 16 Maintenance BATTERY MOUNTING loose battery increases damaging effects of vibrations and 1 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 15 discharged to its 20 state of charge it 1s 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
5. CONVERTER INSTALLATION Installation and Trouble Shooting Guide 5 1200 25 5 1200 25 is state of the DC DC converter There many new features and special is required to install this unit properly If you problems with the cpereticn of this unit piease check the installation procedures for help The ORANGE wire is the INPUT POSITIVE gt The BLACK wire near the orange wire is the INPUT NEGATIVE gt The RED wire is the OUTPUT POSITIVE The BLACK wire near the red wire is the OUTPUT NEGATIVE NOTE Use the correct black wire for input and output Do not connect the black wires together The black wires are common however due to the high currents developed in this unit it is necessary to maintain proper electron flow to reduce noise The converter must be mounted on a RE 2 75 metal surface for proper heat dissipation A N NE RED vertical mounting position is best to maximize the convection process unit will shut down gt thermally under high currents if not properly mounted This unit is equipped with digital logic capabilities The input voltage is monitored to determine acceptability If the input voltage is below the MIN or above the MAX limits the SY1200 25 will NOT tum on 5 0 gt 5 55 gt BLACK The fuse in this unit has no determining factors as to the current carrying capabilities of the converter The fuse serves only one purpose and that is to remove t
6. NN 114 E BEARING 373820 5 166 DE Ne LS TOITS 4614 d IT ct 3620023 2 75 O D OIL SEAL 3620024 3 0 O D OIL SEAL 3113000003 PULLEY W80 8 O D LOCKTITE RTV 3620011 3620022 amp CUP 3620022 amp 36 Spare Parts QTY PART NUMBER 373098 5100 PP 42 B E3AZ D9AZ D9AZ DSAZ D9AZ 0942 D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ 0942 D9AZ D9AZ D9AZ D9AZ 9 2 D9AZ D9AZ D9AZ D8AZ D9AZ D9AZ D9AZ D8AZ D9AZ 0942 D9AZ E7TZ 2 0882 7 2 E6TZ 2672 E5TZ 4033 4036 4067 4067 4067 4067 C 4067 D 4067 E 4067 4067 6 4067 4087 J 4067 K 4067 L 4067 M 4067 N 4067 4067 R 4067 4067 T 4067 0 4061 4067 W 4067 4067 Y 4067 2 4057 4067 4067 4057 0 4067 4067 4236 4N237 A 4241 4 332 4346 4346 4346 4246 4616 4621 DESCRIPTION Plug housing 1 2 14 Cover assy housing also serviced in assy group 4010 Gasket cover to housing use DBAZ 19562 B Shim differential bearing adjustment 241 thick 243 thick 245 thick 241 thick 248 thick 251 thick 253 thick 255 thick 257 thick 259 thick 261 thick 2B3 thick 265 thick 267 thick 269 thick 271 thick 273 thick 275 thick 277 thick 279 thick 281 thick 2
7. S43H5 14 SNOLLdO ELKIRE m ASS Spare Parts PARTS LIST QTY BI 5 1 1 1 2 3 3 E E6 AMBERFRONTLIGHT 2 7 8 BACKUP LIGHT 2 246108 Gio BATTERY e G2 BATTERYCHARGER 1124 G3 _ ___ M1 SEPEX MOTOR 111 M2 SERIES MOTOR 11124 7 MICROSWITCH 13600 1 _ POTENTOMETER 367003 1 _ PLASTIC GEAR 36705 1 LIGHT SWITCH PUSH PULL 486002 1 HYDRAULIC BRAKE LIGHT SWITCH 2374001 1 DC DC CONVERTER I ____ HOUR METER CONNECTOR X2 SPEED CONTROL CONNECTOR 1 X3 CHARGER CONNECTOR 1 _______ ___ 90380 j Consult Motrec Illustrated parts 46 Spare Parts Strobelight polemount Amber 12 80V 3116000001 Red 12 80V 2469001 Blue 12 80V 3690008 Strobelight cab mount Amber 12 48 3116250001 Red 12 48V 3069026 Blue 12 48V 3069014 Amber 72 80V 3116720001 Red 72 80V 3116720002 Blue 72 80V 3116720003 Amber turn lamp 12 3069020 Bulb 12 3069021 Tail Brake light Grommet 3269001 Plug 246012A 2 2469021 24V 2469022 Red Tail Brake light 12 386002 ILLUSTRATED ACCESSORIES Red Tail Brake light Housing 3069012R Bulb 12V 3117240001 Back up lamp Grommet 12V 24 3269001 3669012 3669012 12 Bulb 12V 3069012 12
8. across and After cleaning the power must not be reapplied until terminal areas are thoroughly dry On EE rated vehicles make sure that all the additional protectors are properly installed and that the static strap makes a good contact with the ground Keep cables and wires clear from mechanical and rubbing action Make sure cable insulation 15 free from cutting or visible damage 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 the speed controller 1t can cause accident and severe damage to the motor SEPEX speed controls 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 1 found and part of the text can t be read Maintenance DECALS AND LABELS CAUTION The images included in this section depict the decals markings installed on the vehicle It 1 of prior importance that theses decals markings remain unaltered and readable Else t
9. control bad forward contactor 15 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 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 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
10. 1 2125000001 version BRAKE CONTROLS DESCRIPTION Nut 1 4 20UNC Yoke Lock washer 4 Lubrication fitting Rubber pad Lever Lever Push rod Master cylinder Nut 3 8 16UNF Pivot Boot included with 2125000001 Master cylinder Clevis pin 3 8 x 1 3 32 Cotter pin 3 32 x 1 QTY REF PARTNO 14 2190000003 15 2910000012 16 17 18 19 2139240002 20 2129000003 21 2129000001 22 2921000001 23 2127000006 24 2127000001 25 2191240002 ND 38 DESCRIPTION Spring Extention Yoke Cotter pin 3 32 x 1 Flat washer 5 16 Clevis pin 5 16 x 1 1 2 Handbrake lever Handbrake cable Clip Cable stop Handbrake band side cable Handbrake band Spring compression Spare Parts FRONT AXLE SUSPENSION STEERING DISC BRAKES 51 39 Spare Parts REF I WN 10 11 12 13 14 15 16 17 19 21 22 23 24 25 26 27 28 29 30 31 2208240001 481452 2208240002 481454 3030021 3030020 481457 2200300002 2207000001 2207000002 2910000005 2910000006 2207320001 481460 481462 481472 481464 2205250001 2910300001 2103250001 2914364001 2229300002 2103300001 2224300001 2910300003 2103300002 2229300001 481431 481430 481432 2120236001 2916000001 2192280001 DESCRIPTION STEERING WHEEL NUT 3 4 16 COVER PIN OIL
11. 69008 Pedestral head lamp 12 2569001 Bulb 12V 2569001B Bulb 24V 4469001 Headlight Left Right Bulb H L Bulb Turn Bulb Mark 3111480003 3111480004 3111480006 3111480008 3111480007 Headlight Left 3111480009 Right 3111480010 Bulb H L 3111480011 Bulb Turn 3111480012 Bulb Mark 3111480013 Turn signal switch 246050 Analog Voltmeter 2 3069007 24V 2469002 36 48V 3669002 HOBBS Gauge 24V 2469026 36V 3069038 48V 4869037 246003 246013 47 Horn button VIP 2330014 m Horn button column mount 246210 Horn button dash mount 266210 Horn button 3109250001 Limit switch 3030015 Back up alarm 12 48V 72 80V 3100000001 3105720001 Spare Parts DC DC converter 10 12 48V 3069019 DC DC Converter 25A 12 48V 3124000002 72 80 3124720001 Wiper motor 12V 24V 3113000001 486211 2800000001 Wiper blade 14 Blade 18 Blade Wiper arm 2800000002 2800000003 Em Pantograph wiper arm 246233A Pantograph wiper blade 246233 a Cab heater 12V 3103300001 36V 3669008 48V 4869020 12V Dome light 3669006 12V Fan 3669013 48 Headlamp 12V 3111250001 m vr h 1 BW Vi PUN en s 1 Ini Headlamp 12 Bulb 12V 3111300001 3111300002 AO Red Pilot light 12V Bulb 12V 246212 246212B Spare Parts
12. 83 thick 285 thick 287 thick 289 thick 291 thick 293 thick 205 thick 207 thick Geer kit differential side usa with axle 87200 7245 7300 19871 Consists of 2 772 4228 Washer 2 E7TW 4236 Gear U washer axle shaft retaining Pin differential pinion shaft lock ring axle shaft Bolt housing cover self locking 51167 18 x 5 8 also serviced in assy groun 4010 Use with axle WEC A B 7200 724S 7300 760B 7621 Use with axle 7800 762P Stud housing cover 5 16 18 and 5 16 18 x 1 1 2 long also serviced in amp ssy group 4010 use with axle 760C 762P Cup driving pinion bearing front 888048 Cone and roller drive pinion front bearing 88048 QTY AR AR AR AR AR 10 37 PART NUMBER FORD WEC NON LOCKING REAR AXLE SERVICE PARTS LIST NO 237 D9AZ D9AZ D9AZ D9AZ D9AZ 712 ETTZ 2 D5AZ 0942 712 E7TZ C7AZ C7AZ 7 D5AZ 502 E7UZ 4067 4067 AG 4067 4067 4067 4067 AL 4200 4204 4204 4211 4215 4216 4221 4222 4228 4228 4230 4230 4628 4630 4662 4663 4670 4676 4851 4851 389546 5100 170 E6TZ 4859 4859 DESCRIPTION Shim differentia bearing adjustment Cont d 299 thick 301 thick 303 thick 305 thick 307 thick Differential assy refer to
13. 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 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 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 Maintenance MAINTENANCE WARNING It 1s 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 mainten
14. DRAULIC BRAKES DRUM BRAKES Remove brake drums and check linings wear the linings should have thickness exceeding 1 16 1 5 mm Turn the brake adjustment to reduce the clearance between lining and drum but avoid contact or drag when the wheels are turned and the pedal 1s released DISC BRAKES Check pad linings for excessive wear the linings should have a thickness exceeding 1 16 1 5 mm Disc brakes are self adjusting 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 l 2 Pod vem fill the master cylinder with brake fluid DOT 3 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 14 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
15. ED displays fault codes when there Isa 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 welded main contactor appears as a G a G a 992 2 2 252 The codes are listed in Table 6 Table6 STATUS LED FAULT CODES LED CODES EXPLANATION LED off no power or defective controller solid on controller or microprocessor fault controller operational no faults not used hardware failsafe fault current sensor or motor fault not used throttle fault static return to off SRO fault high pedal disable HPD fault emergency reverse circuit check fault contactor driver overcurrent welded main contactor precharge fault missing contactor or main cont did not close low battery voltage overvoltage thermal cutback due to over under temp anti tiedown fault ho y Re 0 1 1 1 1 2 2 2 2 3 5 3 3 4 4 4 4 NOTE Only one fault is indicated at a time and faults not queued up Refer to the troubleshooting chart Table 5 for suggestions about possible causes of the various faults Curtis PMC 1244 Manual 32
16. MC to measure resistance signal When the micro switch 1 activated the signal must be less than 50 ohms When the front portion of the pedal 1s 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 1s on and then connect terminals 2 and 3 POTENTIOMETER V BRACKET AUXILIARY SWITCH IS WIRED N O WITH BLUE LEAD TO COM amp ORANGE LEAD TO N O CIRCUIT 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 ADJUSTING SCREW ACTUATOR PIN 12 Maintenance BELTINSTALLATION AND TENSIONING INSTALLATION Adjust the sprockets using a straight edge Slide up the edge on the larger pulley until it contacts the smaller pulley Properly adjusted pulleys will provide three points of contact Properly aligned pulleys will provide four points of contact Tighten setscrews and recheck alignment CONTACT TENSIONING Check the force required to provide a deflection of 1 8 in If the measured force is less than 15 lbs then lengthen centre distance C P SPAN LENGTH reme DEFLECTION IN C CENTER DISTANCE 13 Maintenance HY
17. MOTREC HEE T 448HD OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1006000 amp UP Printed 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 I5 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 amp 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 compensation will be a
18. RN OFF Check specific gravity in each battery cell As 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 control Can be caused by a transformer failure 18 Maintenance ELECTRICAL TROUBLESHOOTING WARNING Maintenance work must be performed by trained service technicians only It 1 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 56 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
19. RTNO DESCRIPTION REF PART NO DESCRIPTION 2450003 MOTOR ASS 11 2450007 BRUSH PLATE ASS 1 484001 SEAL 12 2450010 PLUG 2 484002 DRIVE ENDHEAD 13 484013 WAVY WASHER 3 484003 BEARING 14 2450009 COMMUTATOR ENDHEAD 4 484004 SNAP RING 15 484015 HEAD BAND 55 5 484016 ARMATURE FAN 16 2450004 ARMATURE ASS 6 484006 NUT WASHER PACK 17 2450006 SPRINGS 7 2450011 FIELD COIL KIT 18 CALL FACTORY MOTOR BASE 2152002 BELT TENSIONER 19 CALL FACTORY PULLEY 10 2450008 2 BRUSHES amp LEAD ASS 20 CALL FACTORY BELT 41 Spare Parts REAR SUSPENSION REF PART NO DESCRIPTION 2192320001 LEAF SPRING 2185280001 MOUNTING LEAF SPRING 3640004 U BOLT 3 2 I D 5040004 U BOLT 4 I D 2183240002 BUSHING 2182320002 BAR 242057 BOLT 2182448004 REAR SUSPENSION PLATE D Q D 42 Spare Parts ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT OSA SHOLOW H3OHVHO FEL X3d3Ss SYOLOW H39 HVHO pret X3d3S agarang 3 2 ajojo 5 LV Ea EE EIEIEIEIEIEIEIEIEIE1EIEI 1HM So SS 9155151919169 43 Spare Parts ACCESSORIES DC DC CONVERTER ACCESSOIRES CONVERTISSEUR DC DC DC DC CONVERTER ACC 2HL2TL1SLTWM DRAWING ACC DC DC 2HL2TLTSLTWM VSD x a ean NES 44 OPTIONS Spare Parts SA 5 SNOILdO NONOVO f soHinv SNOILdO JUL
20. SEAL BUSHING BUSHING TUBE ROD END LEFT HAND ROD END RIGHT HAND NUT LEFT HAND RIGHT HAND FRONT TIE ROD TIE ROD RIGHT AXLE LEFT AXLE AXLE BEAM KING PIN NUT 3 4 NF THRUST BEARING BUSHING OIL SEAL TAPER BEARING HUB WHEEL BOLT TAPER BEARING DUST CAP RIGHT CALIPER LEFT CALIPER FLEX HOSE DISC U BOLT LEAF SPRINGS NUT 1 2 NF BOLT 5 8 NC REF 32 33 34 36 37 38 39 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 59 60 61 62 63 40 2182320001 2183240002 2180240001 2184448001 481434 481442 481440 481441 2200300003 481466 2117250001 4430002 2207320009 481470 481471 2814003 481474 2910300002 3614002 3614003 2330014 2330013 2230014 2330015 2200224003 2200224001 2200224002 4430001 481466 2230023 2230015 2230016 2230017 DESCRIPTION SHACKLE LINK BUSHING NUT 5 8 NC SHOCK ABSORBER PLATE BOLT LONG BOLT SHORT BOLT WASHER SHAFT SCREW GEAR GEAR FOR TILT TEL STEERING ARM BOLT 7 16 NC LOCK WASHER NUT PADS STEERING SUPPORT CASTELLATED NUT BUSHING LONG BUSHING SHORT HORN COVER STEERING WHEEL ADJUSTABLE COLUMN UNIVERSAL JOINT SHAFT NYLON COUPLER SHAFT UNIVERSAL JOINT SCREW SELECTOR BOX COLUMN MOUNTING PLATE NYLON WASHER NYLON BUSHING Spare Parts D00 4002 SEPEX MOTOR AND DRIVE Ar CRI ES Cr 7 CH y En mr TEA SAS gt gt SS REF PA
21. SEC MAIN CONT INTR MAIN CONTACTOR INTERLOCK ON OR OFF MAIN OPEN DELAY MAIN CONTACTOR DROPOUT DELAY IN SEC STATIC RETURN OFF SRO PEDAL INTERLOCK THREADLE PB 6 CHECK WIRING PRECHARGE ON OR OFF w 9 1 SPEED 1 AS PWM 2 SPEED MODE 2 CREEP SPEED AS PWM OUTPUT CREEP SPEED MODE 3 CREEP SPEED AS PWM OUTPUT 43 Spare Parts SPARE PARTS 34 Spare Parts BODY REF PART NO DESCRIPTION 1 2382320009 SEAT BACK CUSHION 2383320004 SEAT CUSHION 1005003 BUCKET SEAT ON SLIDE ADJUSTER NOT ILLUSTRATED 2 2384300009 BACKREST FRAME 3 4400007 BATTERY COVER 4 2330448002 MOTOR COVER 5 2339448004 CONTROLS COVER 6 300022 5 7X8 LRD WHEEL 300024H 5 7 8 NSH TITAN PREMIUM WHEEL 2223360001 5 00 8 SOLID SOFT RUBBER WHEEL 2314320001 FRONT BUMPER 120003 TRIMMING 9 2803300008 RIGHT HANDLE 2803300009 LEFT HANDLE oo 35 Spare Parts 150 DIFFERENTIAL 2320004 MOUNTING PLATE 23 242063 BREATHER BOLT 1 2 X 3 2320006 SPACER 4420003 RETAINING RING 3620010 4420005 RETAINER T gt J 242054 BOLT 4347 2173448001 P 15 3620020 amp 4215 LOCKTITE RTV Das S 4067 3620020 CONE amp CUP G 42 8 T d A 7j CN 359475 S NN LE OR h 4669 305105 S r 3620021
22. UTPUT 100 2 WAN CURRENT ur PLUG C woezmucamawrUMT 200 2 RAMP C L__ MODE 2 RAMP START CURRENT LIMIT 500 2 ACCEL RATE MODE 2 ACCELERATION RATE IN SECONDS 15 M2 SPEED 2 MAX SPEED AS OUTPUT 100 NEUT BRAKE BRAKE CURRENT LIMIT 200 NEUTRAL BRAKE NEUTRALBRAKEONOROFF oN TITRE MOTREC INC DIAGRAM ELECTRIC T 448 E 660 T 84B 500 AMP PMC CONTROLLER 295 Curtis Speed Controller CURTIS SPEED CONTROLLER 26 MANUAL 27 CURTIS 2701 1244 MultiMode MOTOR CONTROLLER 2001 CURTIS INSTRUMENTS INC DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 1244 Manual p n 16958 Rev B January 2001 1244 Manual p n 16958 Rev B January 2001 2001 CURTIS INSTRUMENTS INC CURTIS INSTRUMENTS INC 200 KISCO AVENUE MOUNT KISCO NEW YORK 10549 USA 914 666 2971 rax 914 666 2188 CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE CALIFORNIA 94550 USA i 925 961 1088 rax 925 961 1099 ADDITIONAL OFFICES located in Bulgaria China England France Germany India Italy Japan Netherlands Puerto Rico Russia Sweden and Switzerland www curtisinst com 28 2 INSTALLATION amp WIRING Controller WIRING Standard Configuration Figure 3 shows the typical wiring configuration for most applications The interlock swit
23. WARNINGS FOR OPERATORS OPERATING INSTRUCTIONS MAINTENANCE SAFETY WARNINGS FOR SERVICE TECHNICIANS DECALS AND LABELS PERIODIC MAINTENANCE CHECKLIST ACCELERATOR BELT INSTALLATION AND TENSIONING HYDRAULIC BRAKES FRONT AXLE AND STEERING BATTERY MAINTENANCE BATTERY CHARGER ELECTRICAL TROUBLESHOOTING SERIES SPEED CONTROLLER ELECTRICAL DIAGRAM CURTIS SPEED CONTROLLER WIRING STANDARD CONFIGURATION DIAGNOSTICS AND TROUBLESHOOTING TROUBLESHOOTING CHART LED DIAGNOSTICS PROGRAMMING PARAMETERS E 480TT T 448HD SPARE PARTS BODY FORD F 150 DIFFERENTIAL BRAKE CONTROLS FRONT AXLE SUSPENSION STEERING DISC BRAKES 200 4002 SEPEX MOTOR AND DRIVE REAR SUSPENSION ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT ACCESSORIES DC DC CONVERTER OPTIONS MOTREC ILLUSTRATED ACCESSORIES CONVERTER INSTALLATION BATTERY DISCHARGE INDICATOR HOBBS CURTIS FOOT PEDAL a O 7 k 10 12 13 14 15 16 18 19 22 24 26 29 30 31 32 33 34 35 36 38 39 41 42 43 44 45 47 49 50 51 Instructions INSTRUCTIONS Instructions SAFETY WARNINGS FOR OPERATORS e FAILURE OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY e 15 the responsibility of the owner of this vehicle to train operators to ensure that they understand the operating characteristics of this vehicle including training in vehicle stability and obey the following safety rules and guidelines Owner shall comply with an
24. ance 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 batteries 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 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
25. at 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 to the right under normal conditions Maintain a safe distance from all objects 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 interrupt a charging cycle disconnect the AC plug disconnecting the DC plug or a battery terminal or operating 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 th
26. ce the forward switch and wiring and repeat the test If the programmer shows the forward switch closing and the vehicle now drives normally the problem has been corrected 30 77 8 DIAGNOSTICS amp TROUBLESHOOTING Table5 TROUBLESHOOTING CHART LED PROGRAMMER LCD DISPLAY HW FAILSAFE1 2 3 FAULT CATEGORY self test or watchdog fault 1 Controller defective M SHORTED Internal M short to B 1 Controller defective FIELD field winding fault 1 Motor field wiring loose 2 Motor field winding open ARM SENSOR armature current sensor fault 1 Controller defective FLD SENSOR THROTTLE FAULT 1 THROTTLE FAULT 2 field current sensor fault wiper signal out of range pot low fault 1 Controller defective 1 Throttle input wire open 2 Throttle input wire shorted to or B 1 Throttle pot defective 2 Wrong throttle type selected SRO SRO fault HPD fault 1 Improper sequence of KSI interlock and direction inputs 2 Wrong SRO type selected 3 Interlock or direction switch circuit open 4 Sequencing delay too short 1 Improper seq of direction and throttle inputs 2 Wrong HPD type selected 3 Misadjusted throttle pot 4 Sequencing delay too short BB WIRING CHECK emergency reverse wiring fault 1 Emergency reverse wire open 2 Emergency reverse check wire open CONT DRVR OC cont driver outp ut over
27. ch 1s turned on When it 1 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 s 3069038 48V UNIT 4869037 2 Orange key switch 3 Relay 4 Relay 5 Black battery 6 Blue hour counter 8 White battery 50 Spare Parts CURTIS FOOT PEDAL BLUE KEY SWITCH GREEN HOUR METER BLACK POTENTIOMETER WHITE POTENTIOMETER OU D RESP CLAUDE L MODEL E PART NO 3062001C 367008 2262004C 2262001C 2262003C 3662002 3 DESCRIPTION ACCELERATOR CURTIS POTENTIOMETER SPRING MICRO SWITCH LEVER CABLE PROTECTOR 321A320001 SER 1018799 51 TO E 320 360 480 500 1019973
28. ch is typically a seat switch tiller switch or foot switch Standard Power Wiring Motor armature winding is straightforward with the armature s Al connection going to the controller s B bus bar and the armature s A2 connection going to the controller s M bus bar The motor s field connections F1 and F2 to the controller are less obvious The direction of vehicle travel with the forward direction selected will depend on oJ CONTACTOR COIL FORWARD REVERSE 5 0 THROTTLE TYPICAL MODE SELECT 2 MODE SELECT 1 INTERLOCK KEYSWITCH MAIN CONTACTOR DIODE CONTROL FUSE Fig 3 Standard wiring configuration Curtis PMC 1244 controller Curtis PMC 1244 Manual 29 8 8 DIAGNOSTICS amp TROUBLESHOOTING Curtis PMC 1244 Manual DIAGNOSTICS AND TROUBLESHOOTING The 1244 controller provides diagnostics information to assist technicians troubleshooting drive system problems The diagnostics information can be obtained by observing the appropriate display on the handheld programmer the fault codes issued by the Status LED or the fault display driven by the controller s Fault 1 and Fault 2 outputs Refer to the troubleshooting chart Table 5 for suggestions covering a wide range of possible faults PROGRAMMER DIAGNOSTICS The programmer presents complete diagnostic information in plain language Faults are displayed in the Diagnostic Menu see
29. column 2 in the troubleshooting chart and the status of the controller inputs outputs is displayed in the Test Menu Accessing the Diagnostic History Menu provides a list of the faults that have occurred since the diagnostic history file was last cleared Checking and clearing the diagnostic history file is recommended each time the vehicle 1 brought in for maintenance The following 4 step process is recommended for diagnosing and trouble shooting an inoperative vehicle 1 visually inspect the vehicle for obvious problems 2 diagnose the problem using the programmer 3 test the circuitry with the programmer and 4 correct the problem Repeat the last three steps as necessary until the vehicle is operational Example A vehicle that does not operate in forward is brought in for repair STEP 1 Examine the vehicle and its wiring for any obvious problems such as broken wires or loose connections STEP 2 Connect the programmer select the Diagnostics Menu and read the displayed fault information In this example the display shows No Known Faults indicating that the controller has not detected anything out of the norm STEP 3 Select the Test Menu and observe the status of the inputs and outputs in the forward direction In this example the display shows that the forward switch did not close when forward was selected which means the problem is either in the forward switch or the switch wiring STEP 4 Check or repla
30. ctions 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 FOOT BRAKE PEDAL It is designed for right foot operation only The brake force 15 proportional to the pressure on the pedal PARKING BRAKE Pull handbrake lever to apply Never park the vehicle on an incline Always turn off all switches set the F R selector to neutral set the parking brake remove the key before leaving the vehicle E Maintenance MAINTENANCE Maintenance SAFETY WARNINGS FOR SERVICE TECHNICIANS FAILURE OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY Owner shall comply with OSHA and ASME ANSI B56 8 amp 56 9 regulations for vehicle maintenance Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect carriers vehicles tractors and batteries Before any
31. current 1 Contactor coil shorted MAIN CONT WELDED welded main contactor 1 Main contactor stuck closed 2 Main contactor driver shorted PRECHARGE FAULT MISSING CONTACTOR internal voltage too low at startup missing contactor 1 Controller defective 2 External short or leakage path to B on external connection 1 Any contactor coil open or not connected MAIN CONT DNC LOW BATTERY VOLTAGE OVERVOLTAGE main contactor did not close low battery voltage overvoltage 1 Main contactor missing or wire to coil open 1 Battery voltage undervoltage cutback limit 2 Corroded battery terminal 3 Loose battery or controller terminal 1 Battery voltage overvoltage shutdown limit 2 Vehicle operating with charger attached 3 Battery disconnected during regen braking THERMAL CUTBACK over under temp cutback 1 Temperature gt 85 C lt 25 C 2 Excessive load vehicle 3 mounting of controller 4 Operation in extreme environments ANTI TI EDOWN Curtis PMC 1244 Manual Mode 2 or Mode 4 selected at startup 31 1 switches shorted 2 Mode switches tied down to select Mode 2 or Mode 4 permanently 78 8 DIAGNOSTICS amp TROUBLESHOOTING LED DIAGNOSTICS A Status LED is built into the 1244 controller It is visible through a window in the label on top of the controller This Status L
32. 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 gravity of each cell if a cell is shorted voltage drop may occur only when there is current 17 Maintenance WARNING Always unplug the AC and DC electrical cords before attempting any repairs to the charger CHARGER DOES NOT TURN ON 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 be caused by a transformer failure AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES Check the battery pack CHARGER DOES NOT TU
33. d ASME ANSI 56 8 amp 56 9 regulations for vehicle use safety rules operator training and certification Do not drive this vehicle unless you are a qualified operator e Do not drive this vehicle under the influence of drugs or alcohol Donotdrive this vehicle on public roads and highways This vehicle 1 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 Donotopen battery compartment to prevent battery explosion acid splashing severe damage to eyes or skin e 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 Donot 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 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 th
34. e driver uses brakes when you slow or stop the towing vehicle Do not exceed 5 MPH or carry any passenger while towing this vehicle E 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 ANSI B56 Do not drive this vehicle unless you are a qualified operator BEFORE USING VEHICLE Before turning on key switch set to neutral check for any visible damage check brake pedal 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 BATTERY CHARGER Park the vehicle 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 1 fully charged To interrupt the charging cycle disconnect the AC plug 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 1s 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 instru
35. group in Section 40 Case assy differential Use with axle 7200 724S 730D 1987 Shaft differential pinion kit use with axle 87200 7245 7300 1987 Consists of 1 E7TW 4211 Shaft 1 0887 4241 Pin Pinion kit use with axle 720 7245 7300 1987 Consists of 2 E7TW 4215 Pinion 2 7 2 4230 Washer Bolt differentlal case self locking 7116 20 x 3 4 Cone and roller differential bearing LMB03049 Cup differential bearing LM603012 Washer differential side gear thrust also serviced in kit group 4236 Use with axle 37200 7245 7300 1987 Washer differential pinion thrust also serviced in kit group 4215 Use with axle 7206 7245 7300 1987 Cup driving pinion bearing rear 8 802011 Cone and roller drive pinion rear bearing 802048 Spacer driving pinion bearing 1 5 16 1 0 x 15 32 long collapsible also serviced in kit groun 4209 Shim pinion bearing serviced only in kit aroup 4209 Slinger pinion shaft oil Seal assy drive pinion oil ESDW 4676 Flange assy universal joint axlo end 1330 size 1987 Locknut and washer assy flange to piaion 3 4 20 also serviced in kit group 4209 Deflector driving pinion oil sea Plastic From 1 86 1956 Spare Parts REF N D 10 11 12 13 PART NO 2910000015 2930000012 2131100002 2131360002 2131360012 2133280001 213232000
36. he sticker or the part bearing the marking has to be replaced Dashboard security warning label Operation of this vehicle is restricted to authorized persons only Head operator s instructions in owner s manual prior to driving General security warning label Operation of this vehicle is restricted to authorized persons only Head operator s instructions In owner s manual prior to driving Do not operate on roads public streets and unauthorized areas open battery compartment Never open motor compartment Warn people to stay away from wheels and moving or lifting parts Never exceed specified max speed cargo passenger capacity Drive slowly on ramps in turns in reverse Avoid loose cargo Before turning on key switch and while moving be sure that occupants keep all their body parts inside vehicle occupants keep holding on hand rails wheel chair if applicable is secured with tie down straps trailer attachment if applicable is secured with two chains Before leaving this vehicle park on a flat surface set to neutral set the parking brake turn off all switches and remove the key Respectively key switch markings forward reverse selector markings and light switch marking ke ESPR F WD 10 Maintenance PERIODIC MAINTENANCE CHECKLIST WARNING Maintenance operations must be made by properly trained service technicians Keep clear from moving parts such as tires sheaves a
37. he unit from your power source in the event of a failure The 5 1200 25 has a very advanced control section and will determine when to open the fuse An open fuse will mean that a problem had occurred that does not mean that the problem still exists or that the problem has gone away DO NOT increase or by pass the fuse USE ONLY A FUSE RATED AT 250V 20A Potential reasons for an open fuse are as follows 1 The output voltage rises above 18 VDC This problem can occur when an inductive load is removed or applied at high currents This is a noise spike and the converter will shut down if it can not suppress the spike 2 Reverse polarity on the input or output 3 A chaos condition where the output becomes unstable 4 Excessive noise or spikes on the input Mount this unit as close to the highest current load as possible This unit uses true switching techniques to step down the input voltages The higher the input voltage the lower the input current for a 25 load The high currents on the output of the converter Use 14 gauge wire for the input up to 5 feet Use 12 gauge wire for up to 10 feet Increase the wire gauge for each additional 5 feet of wire NEVER use less than a 10 gauge wire on the output If the wire length exceeds 5 feet use 8 gauge wire IMPORTANT Use a crimp type of connector to attach the wire to the converter DO NOT twist the wires together A poor connection will not only allow the converter to operate
38. 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 19 12 2005 Table contents TABLE OF CONTENTS INSTRUCTIONS SAFETY
39. llowed 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 hazard The driver
40. 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 wrench 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
41. nd 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 adequate capacity identify and disconnect battery leads Don t connect the charger PERIOD DAY WEEK QUART YEAR 2 YEARS CHECK PERFORM HOURS 20 50 200 1000 2000 MECHANICAL DAMAGE OIL LEAKS X 144 REVERSE ALARM DEADMANSWITCH X S TIRE PRESSURE pressure rating on tire _ J jJ X o j CHECK FILL BATTERIES add distilled X water to cover plates Fill to recommended level after batteries have been fully charged MASTER CYLINDER FLUID DOT 3 05 LX ql 2 50 mm maximum travel STEERING FOR PLAY TT CS STEERING FOR PLAY requires 10 165 5 force to apply BELTS AND PULLEYS X 10 Ibs 5kg force for 1 8 3mm deflexion pulleys alignment see procedure qq X 1 p CLEAN TIGHTEN WIRE TERMINALS WASH BATTERY TOP WITH WATER MOTOR BRUSHES FOR WEAR brushes must exceed holders
42. poorly but at 25 5 the connection WILL GET HOT AND BURN IN TWO WARNING THE CHASSIS IS ISOLATED FOR HIGH VOLTAGE APPLICATIONS DO NOT USE THE CHASSIS FOR GROUND 49 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 15 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 1s adjustable via potentiometer on the rear 1 84 In order to activate new adjustment the unit has to be reset 2 35V cell reset voltage with battery remaining in vehicle 2 09 V cell reset voltage after battery has been disconnected To maintain a good battery performance it is recommended to limit the discharging to 80 of the battery capacity The recommended setting for 6V batteries 1 and the recommended setting for an industrial battery 1s K An internal relay can prevent overdischarging and damaging the batteries The relay can be wired to cut off the reverse 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 1 indicated for a period of 5 seconds after the key swit
43. s and check the motor armature and field for opens 21 Series Speed Controller SERIES SPEED CONTROLLER 22 MANUAL 1214 8 1215 8 1219 8 MultiMode MOTOR CONTROLLERS 2003 CURTIS INSTRUMENTS INC DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 1214 8 1215 8 1219 8 Manual 16369 Rev April 2003 23 Series Speed Controller ELECTRICAL DIAGRAM DIAGRAMME LECTRIOUE JONVUO 3533434 39NV30 24 Series Speed Controller CREEP SPEED p sionaTion REF ore a n ___ _ een 5 eevesecomacrn EMERGENCY PUSH BUTTON mm J _ bom e EE mew m eosar eana 1 afo as r wm o emome e omur memen maso aen PARAMETERS CREEP SPEED AS PERCENT DUTY CYCLE EMR REV SPEED EMR REVERSE SPEED AS PWM DUTY CYCLE senvenena ver SEONG VARIABLE PLUG THROTTLE VAR So ennemi M1 MAIN L L MODE 1 CURRENT LIMIT QUICK START THROTTLE FACTOR nr EN ANTI TIEDOWN ON OR OFF 30 500 200 500 RAMP L MODE TRAMP START CURRENT LIMIT MIPLUGC L MODETPLUGCURRENTLMT M1 ACCEL RATE MODE 1 ACCELERATION RATE IN SECONDS M1 MAX SPEED MODE 1 SPEED AS PWM O
44. 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 HPD safety feature that prevents the vehicle from moving if the accelerator pedal is depressed before the key switch 15 ON and seat switch 15 activated may also have an SRO safety feature that prevents the vehicle from moving if the F R switch 15 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 1 also equipped with an internal thermal protection that cutback the current until the PMC has cooled down 20 Maintenance NO MOTION Make sure that the PMC surface 15 clean and dry check the terminal areas Dust Particles or acid contamination can create current leaks and cause 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 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
45. 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 the battery gage if not B check wiring Turn the key switch ON check 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 1f 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 1s the most probable cause of the problem Switch to reverse and check voltage on the reverse control wire If not 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 19 Maintenance REVERSE ONLY On a SEPEX motor control check the forward signal Input on the controller serles wound motor
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