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1. LU 660 AAS OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1021002 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 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 wil
2. NEG NEGATIVE of the battery pack Note This is a Class A product In a domestic environment this product may cause radio c Check that the correct charge algorithm is being used referto interference in which case the user may be required to take adequate measures section 4 Securely fasten the red ring terminal to the positive 2006 Delta Q Technologies Corp All rights reserved PN 710 00xx Rev 1 V1 16 terminal POS POSITIVE of the battery pack 3 E 66 Horn button VIP 2330014 Horn button column mount 246210 Horn button dash mount 266210 3109250001 Horn button Limit switch 3030015 Back up alarm 12 48 72 80 3100000001 3105720001 Red Tail Brake light 12V 386002 Headlight Left Right Bulb H L Bulb Turn Bulb Mark 3111480003 3111480004 3117480001 3117480003 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 246003 246013 MOTREC ILLUSTRATED ACCESSORIES Red Tail Brake light 3069012R 3117240001 3269001 3669012 3669012A 3069012 1269008 Housing Bulb 12V Back up lamp Grommet 12V 24V Clear lamp 12V Bulb 12V Pedestral head lamp
3. 43 Shim differential bearing adiusiment Cont d 299 thick 301 thick 303 thick 305 thick 307 thick Differential essy refer to group in Section 40 Case assy differential Use with axle 87200 7245 7300 1987 Shalt differential pinion kit use with axle 87206 7245 7300 1987 Consists of 1 E7TW 4211 AA Shall 1 0887 4241 4 Pin Pinion kit use with axle 7200 7245 7300 1987 Consists of 2 E7TW 4215 Pinion 2 E7TZ 4230 Washer Bolt differential case self locking 7116 20 x 3 4 Cone and roller differential bearing 09 Cup differential bearing LM603012 Washer differential side gear thrust also serviced in kit group 4236 Use with axle 47200 7245 730D 1987 Washer differential pinion thrust also serviced in kit group 4215 Use with axle 27206 7245 7300 1987 DESCRIPTION driving pinion bearing rear 8 802011 Cone and roller drive pinion rear bearing 8 802048 Spacer driving pinion bearing 1 5 16 1 0 x 15 32 long collapsible also serviced in kit group 4209 Shim pinion bearing serviced only in kit aroup 4209 Slinger pinion shaft oii Seal assy drive pinion oil HESDW 4676 AA Flange assy universal joint axle end 1330 size 1987 Locknut and washer assy flange to pinion 3 4 20 also serviced in kil qroup 4209 Deflector driving pinion oil seal Plastic From 1 86 1986 4067 4067 AG 4067 40
4. 2569001 2569001B 4469001 3111480003 3111480004 3111480006 3111480008 3111480007 67 12V Bulb 12V Bulb 24V Headlight Left Right Bulb H L Bulb Turn Bulb Mark Spare Parts Strobelight polemount Amber 12 80V 3116000001 Red 12 80V 2469001 Blue 12 60 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 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 3269001 Plug 246012A 12 2469021 24 2469022 Headlamp 12V 3111300001 Bulb 12V 3111300002 Red Pilot light 12V 246212 Bulb 12V 246212B Pantograph wiper blade 246233 Cab heater 12V 36V 48V 3103300001 3669008 4869020 3669006 amp 12V Dome light 12V Fan 3669013 Wiper motor 12V 24V 3113000001 486211 SG Wiper arm 280000000 I Wiper blade 14 Blade 18 Blade 2800000002 2800000003 I Pantograph wiper arm 246233A 68 Spare Parts BATTERY CAPACITY Analog Voltmeter 12V 3069007 24V 2469002 36 48V 3669002 HOBBS Gauge 24V 2469026 36V 3069038 48V 4869037 DC DC converter 10A 12 A8V 3069019 DC DC Converter 25A 12 48V 3124000002 72 80V 3124880001 Spare Parts BATT
5. Forward Reverse Wiring The forward reverse wiring schemes described here all assume the power wiring shown by the heavy lines in Figure 8 Some vehicles especially those previously using older resistor type controllers may reverse the motor armature rather than the field winding Be careful if you are replacing this type of controller When using the Curtis PMC controller it is essential that the field be reversed and that the armature be connected directly to the controller s B and A2 terminals because the plug diode inside is connected to these terminals Curtis PMC 1204X 1205X 1209 1221 Manual 36 13 MAINTENANCE 8 ADJUSTMENT MAINTENANCE 8 ADJUSTMENT Curtis PMC 1204X 1205X 1209 1221 controllers and potboxes require only minimal maintenance if properly installed NOTE The controllers are sealed and thus are not field serviceable CONTROLLER Maintenance It is recommended that the following two steps be performed occasionally First remove power by disconnecting the battery and discharge the capacitors in the controller with a light bulb or a 2 10 25 W resistor connected for a few seconds across B B Follow good safety practices get the vehicle drive wheels off the ground wear safety glasses and use insulated tools see page 2 1 Make sure the electrical connections to the controller and to the motor contactors etc are tight When checking the controller bus bar connec tions for tightness use t
6. 2185320001 PLATE 2185501001 PLATE 2189660002 SHAFT 2192660001 LEAF SPRINGS 2224300002 HUB 2229300001 DUST CAP 2229300002 OIL SEAL 2229300003 SPINDLE WASHER 2910000019 WHEEL NUT 2910300002 CASTELLATED NUT 1 UNEF 2916000001 U BOLT 1 2 NF X 2 2916280002 U BOLT 1 2 NF X 3 1 4 ID 2916480002 U BOLT 1 2 NF X 4 ID 2930000012 GREASE FITTING BOLT 1 2 NC X 2 2 2 BOLT 1 2 NF X 3 BOLT 1 2 NF X 9 BOLT 5 8 NC X 6 GRADE 8 BOLT 3 4 NC X 6 GRADE 8 FLAT WASHER 32 FLAT WASHER 12mm COTTER PIN 3 16 X 2 LOCK WASHER 1 2 LOCK WASHER 5 8 LOCK WASHER 3 4 NUT 1 2 NC HEAVY NUT 1 2 NF NUT 1 2 NF NUT 3 4 NC NUT 3 8 NC 54 Wide Frame 48 Wide Frame LC Internal Combustion 2592 A WN m Un Spare Parts S3 FRAME REAR SUSPENSION 7000 LBS OPTIONAL Spare Parts 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 LEAF SPRING STOPPER KIT LEAF SPRING STOPPER UPPER PART LEAF SPRING STOPPER RUBBER 7 LEAF SPRINGS BOLT LONG BOLT SHORT U BOLT 1 2 NF X 3 1 4 LD U BOLT 1 2 X 4 LD BOLT 5 8 NC X 7 GRADE FLAT WASHER 12mm FLAT WASHER 3 8 MACHINE SCREW 1 4 NC X 3 8 HEX SOCKET CAP SCREW FLAT HEAD 3 8 NC X 4 NYLON NUT 5 8 NC LOCK WASHER 3 8 HEAVY NUT 1 2 NF NUT 3 8 NC BUSHING
7. 60 61 63 64 65 66 67 69 70 71 72 73 74 75 76 77 78 79 47 DESCRIPTION BUSHING BUSHING WITH OIL SEAL BUSHING THRUST BEARING TAPER BEAING TAPER BEAING 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 SHACKLE LINK PLATE LEAF SPRINGS TUBE SHAFT LEFT SPINDLE AXLE BEAM AXLE BEAM RIGHT SPINDLE 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 REAR TIE ROD FRONT TIE ROD ARM STEERING WHEEL COVER SPACER Spare Parts PART NO 2100300002 2100300001 2100300003 2103250001 2103300001 2103300002 2104300004 2117250001 2120236001 481431 481430 2121000005 2121000006 2122300001 2122300002 2128280001 2128280001 2129000001 2134000001 2139000001 2139000002 2139000003 2180240002 2182660002 2182660005 2185660001 2192606001 2200300002 2200300003 2201360002 220 1660001 2201660006 2201660010 2205250001 2206300003 2206320001 2207000001 2207000002 2207660001 2207660003 2207660005 2207660011 2208240001 2208240002 2219250001 33 34 35 36 37 39 40 54 Wide Frame A8 Wide Frame PART 484003 484004 484006 484013 484015 A91 107A 3122230001 245000
8. SIDE MIRROR BRACKET WIPER MOTOR WIPER ARM DOOR HANDLE DOOR HANDLE BAR DOOR LEVER REAR GLASS WINDSHIELD PART NO 2801000001 2399000014 3113000001 2800000002 2800000001 2366320001 2366660001 2366320003 2367300001 2367300002 CAB 11 12 13 14 15 42 DESCRIPTION STEEL CAB SEATBACK CAB RIGHT DOOR LEFT DOOR PADDLE LATCH DOOR LATCH RIGHT HINGES KIT LEFT HINGES KIT RIGHT DOOR GLASS LEFT DOOR GLASS REAR VIEW MIRROR TRIM DOOR Spare Parts REF PART NO 2360660006 2382320009 2360660007 2360660008 2803000003 2366320015 2365000001 2365000002 2367660002 2367660001 2801000002 2802000001 1 2 Spare Parts FORD F 150 DIFFERENTIAL 242063 BREATHER o g 242054 BOLT 2520007 CONE amp CUP 90 4230 LOCKTITE RTV B 6 4067 3620020 A c 37383 amp CUP n r PF 42 B 359475 5 11 d aE 305105 5 E s 3620021 373820 5 XX 155 A BEARING Nd 285130 5 MM 169 JE ur TA aia 3620023 2 75 O D OIL SEAL 2939 5 B253 3620024 3 0 0 0 OIL SEAL 3821005 PULLEY WED O D 3621006 PULLEY W30 9 G D Na RT 2520011 GEAR KIT z 9620022 CONE CUP 2320004 MOUNTING PLATE NEW 2320006 SPACER 20003 RETAINING RING 4420005 RETAINER 242054 BOLT TYPE Fi HOUSING CALL FACTORY 4420002 OIL SEAL AXLE CALL FACTOR Y
9. 1sod aanisod jes Japeq 1500 ejeipeuuejui ue JE peloeuuoo si punoJ6 seuossaooy La NYS N49 9 i 5 i IHM Jf 8 1 2 Lo 1 NS NE z nis T s T 73A 86 lice ee oa ee tn LS iva i GR 18 148 RED BLK ASAAMLISLEILCIHZ 90 90 ON 99V ONIMVHO JOHLAV NOIS4JA YILYIANOD 90 00 S3IHOSS3OOV FTLIL LO 90 70 9002 INMVISVILC HC r a dea RED WHT _ NY BLK RED ACCESSOIRES SANS CONVERTISSEUR DC DC ACCESSORIES NO DC DC CONVERTER Spare Parts 58 GRN 6 gt RED BLK WHT po REDMWHT BRN 4 N m YEL m X ce Rm T 7 AE AA cec A mim us vei a la wana 1g na ASA AMLISFILTIHZ 90 90 29 ONIMVHQ NONDVOT YOHLNV 4414 93ANO9 90 94 S3lIHOSS3OOV LIL J4o3rans Mia NMO x m 9 r Aa U pm i deca r BLK RE 22 v0 S002 NMLTISLILGIHE LOIN ACCESSOIRES CONVERTISSEUR DC
10. 54 PART NO 2120236001 481431 481430 2121000005 2121000006 2122236001 2122300001 2122300002 2128280001 2128280001 2129000001 2134000001 2139000002 2139000003 2182320002 2185660002 2189660003 2189660004 2189660008 2192320002 2910000017 2910000018 2916280002 2916480001 2183240002 REF N Spare Parts 85 OSA 6 5 4 ONIMVUO 22 21 9002 NOISYJA 1 NIVIN XAdAS 93HION KAS 5 NN SN SN SSS OSS N enne BLK gt TOOVM 18 JOOV O3H v 4 I8 LHAX M 18 9HO BLK dt CIRCUIT PRINCIPAL SEPEX ELECTRICAL DIAGRAM DIAGRAMME ELECTRIQUE SEPEX MAIN CIRCUIT Spare Parts 56 LHM gt 1 ad ne g RED BLK BLK m T a L m d E 6 PX o s 2 T a BLU ORG 4 JO es QSAH39HVHO XSO0CL SSIWAS ONIMVAA 06 NOISH3A SARIS LINDUID NIVA YJ9YYH9 XS0cI S3ld3s Il93arens ELECTRICAL DIAGRAM SERIES MAIN CIRCUIT CIRCUIT PRINCIPAL SERIES DIAGRAMME ELECTRIQUE Spare Parts 57 S9lJOSS929e eu uo Buipuedep AZ Joue SI U9YE JOU SI uondo JelJeAuoo
11. GM PLATE 4 LEAF SPRINGS 5 LEAF SPRINGS 7 LEAF SPRINGS HEAVY DUTY BOLT LONG BOLT SHORT U BOLT 1 2 X 2 LD U BOLT 1 2 NF X 3 147 LD U BOLT 1 2 NF X 2 3 4 LD 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 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 50 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 20 30 31 2183240002 E 302 amp 348 Spare Parts 51 A 4 0 gt 1 NS AD 4 7 2 V B T L a M 3 A 3 W A j N 2 2 REAR SUSPENSION TAMDEM OPTIONAL Spare Parts PART NO DESCRIPTION 2100300002 BUSHING 2103300001 TAPER BEAING 2103300002 TAPER BEAING CALL FACTORY DIFFERENTIEL FORD 2177661001 HYDRAULIC HOUSING 2177501001 HYDRAULIC HOUSING 2179660002 REAR AXLE BEAM 2179660006 REAR AXLE BEAM 2180240002 SHOCK ABSORBER 2182660009 SHACKLE LINK 2183660002 PIVOT 2185280001 PLATE
12. Lock washer 14 Lubrication fitting Rubber pad Lever Lever Push rod Master cylinder Nut 3 8 16 Pivot Boot included with 2125000001 Master cylinder Clevis pin 3 8 x 1 3 32 Cotter pin 3 32 x 1 Spare Parts PART NO 2910000015 2930000012 2131100002 2131360002 2131360012 2133280001 2132320001 2125000001 REF x oo ON ON HB D Ne 10 1 12 13 EE version Spare Parts FRONT ASSEMBLY 46 DESCRIPTION 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 NF SPRING PIN 14 X I 3 4 SET SCREW 5 16 NC CASTELLATED NUT 3 4 NF CASTELLATED NUT 1 UNEF BUSHING U BOLT GREASE FITTING BOLT 1 2 NC X 2 1 2 BOLT 5 16 NC X 1 1 4 BOLT 5 16 NC X 1 BOLT 5 8 NC X 4 BOLT 7 16 NC X 2 CARRIAGE BOLT 1 4 NC X 3 4 NUT 1 4 NC NUT 5 16 NC HEAVY NUT 1 2 NF 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 A NC X 3 8 NYLON NUT 1 2 NC NYLON NUT 5 8 NC LOCK WASHER 1 4 LOCK WASHER 5 16 LOCK WASHER 7 16 PART NO 2224300002 2229300001 2229300002 2229300003 2910000005 2910000006 2910000017 2910000018 2910000019 2910000020 2910000021 2910000022 2910000023 2910000024 2910300001 2910300002 2914364001 2916000001 2930000012 REF 41 42 43 44 45 46 47 48 50 51 52 53 54 55 57 58
13. 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 1s 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 has an HPD safety feature that prevents the vehicle from moving 11 the accelerator pedal is depressed before the key switch 1s ON and seat switch 15 activated PMC may also have an SRO safety feature that prevents the vehicle from moving if the F R switch 1s 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 is 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
14. WIRING Standard Configuration Figure 3 shows the typical wiring configuration for most applications The interlock switch 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 MAIN CONTACTOR FORWARD REVERSE 5 kQ 0 THROTTLE TYPICAL MODE SELECT 2 MODE SELECT 1 INTERLOCK KEYSWITCH MAIN CONTACTOR PROTECTION DIODE CONTROL FUSE B Fig 3 Standard wiring configuration Curtis 1244 controller Curtis PMC 1244 Manual 25 8 8 DIAGNOSTICS 8 TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING The 1244 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 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
15. 28 29 30 32 34 37 40 41 42 43 45 46 48 49 51 53 55 56 57 58 59 61 62 63 64 67 69 70 71 Table of contents TABLE OF CONTENTS INSTRUCTIONS SAFETY 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 CURTIS SPEED CONTROLLER WIRING STANDARD CONFIGURATION DIAGNOSTICS AND TROUBLESHOOTING TROUBLESHOOTING CHART LED DIAGNOSTICS PROGRAMMING PARAMETERS E 290HD E 348 E 480 E 500 E 660 T 248 T 448 CURTIS PMC MOTOR CONTROLLER OVERVIEW WIRING STANDARD CONFIGURATION MAINTENANCE AND ADJUSTMENT SPARE PARTS BODY CAB FORD F 150 DIFFERENTIAL BRAKE CONTROLS FRONT ASSEMBLY MOTOR AND DRIVE REAR SUSPENSION AND BRAKE REAR SUSPENSION TAMDEM REAR SUSPENSION 7000 LBS ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT ELECTRICAL DIAGRAM SERIES MAIN CIRCUIT ACCESSORIES NO DC DC CONVERTER ACCESSORIES DC DC CONVERTER OPTIONS BATTERY CONFIGURATIONS 48V BUILT IN PORTABLE 25A CHARGER BUILT IN PORTABLE CHARGER MODEL 16510 DELTA Q HF CHARGER MOTREC ILLUSTRATED ACCESSORIES BATTERY DISCHARGE INDICATOR HOBBS ADDENDUM CURTIS FOOT PEDAL Instructions INSTRUCTIONS Instructions SAFETY WARNINGS FOR OPERATORS e FAILURE TO OBE
16. 8 at 1 5 mm 1 16 for potboxes without the microswitch When adjustment is correct tighten the screw holding the lever on the pot shaft then recheck to see that this action did not disturb the adjustment Make sure that the lever is still seated down on the pot shaft below the slight bevel on the end of the shaft 3 Check the resistance with the lever pushed all the way to the other stop It should be between 4500 and 5500 ohms If it is outside this range the potbox is faulty and should be replaced 4 For potboxes equipped with a microswitch check for correct switch operation Use an ohmmeter or simply listen for the slight click the switch makes It should operate when the lever is 1 5 mm 1 16 from the return stop If it does not adjust by loosening the two screws holding the slotted microswitch mounting plate to the stop spacers and moving the plate Recheck the switch operating point after tightening the screws Curtis PMC 1204X 1205X 1209 1221 Manual 39 24 Spare Parts SPARE PARTS 40 Spare Parts BODY 773 REF NO PIECE DESCRIPTION 1 1005003 SIEGE BAOUET AVEC GLISSIERE 120003 GARNITURE 3 2223360001 500X8 SOFTY WHEEL ASS 300022 5 7X8 L R D WHEEL ASS 2207004 MOLD ON GREY RUBBER WHEEL 2223480001 6 9 X 9 12PL TUFF GUARD 4 CONTACTER MANUF COUVERCLE DE PLATE FORME CONTACTER MANUF COUVERCLE DE PL FORME TANDEM 5 2311000006 PARE CHOC AVANT amp ARRIERE 41 DESCRIPTION SIDE MIRROR
17. 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 15 Maintenance BATTERY MAINTENANCE WARNING It 18 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 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 B and B identify battery polari
18. SERVICE TECHNICIANS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY Owner shall comply with and ASME ANSI B56 8 amp B56 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 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 repla
19. and 1209 1221 electronic motor speed controllers are designed to provide smooth silent cost effective control of motor speed and torgue on a wide variety of industrial electric vehicles Like all Curtis PMC 1200 series controllers the 1204X 1205X and 1209 1221 models offer superior operator control of the vehicle s motor drive speed Key features of these controllers include Infinitely variable drive and brake control Power MOSFET design provides high efficiency for reduced motor and battery losses and silent operation High pedal disable HPD function monitors throttle status during turn on and prevents operation until throttle has been returned to neutral optzonal feature Thermal protection and compensation circuit provides both under temperature and overtemperature cutback as well as steady current limit throughout the entire operating range Undervoltage cutback function protects against low battery voltage includ ing low voltage caused by external loads More Features t Fig 1 Curtis 1205X full feature electronic motor controller Models 1204X 1209 and 1221 have identical connections Curtis PMC 1204X 1205X 1209 1221 Manual a 32 OVERVIEW v Fault detection circuitry monitors battery throttle connections output transistors bypass contactor etc to prevent runaway conditions Static return to off SRO function requires that forward or reverse selectors be return
20. 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 19 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 18 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
21. 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 15 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 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 Operation of this vehicle is restricted to authorized persons only Read operator s instructions in owner s manual prior to driving General security warning label Operation of this vehicle is restricted to authorized persons only Read operator s instructions in owner 5 manual prior to driving Do not operate on roads public streets and unauthorized areas Never 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 or 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 remain 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 is secured with tie down straps
22. 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 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 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 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 REVERSE ALARM DEADMAN SWITCH IX STATIC STRAP min 27 contact with ground X _ j X CHECK FILL BATTERIES add distilled water to cover plates Fill to recommended level after batteri
23. when there isa problem with the controller orwith 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 Uu G 0 OD gu 3 2 252 3 2 The codes 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 M 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 ONDE m omi RK 55595559 nm mm NOTE Only one fault is indicated at a time and faults are not gueued up Refer to the troubleshooting chart Table 5 for suggestions about possible causes of the various faults Curtis PMC 1244 Manual 28
24. 10 TRANSFORMER ccn SHUNT 2 WHITE TPU AMME T ER CIRCUIT BR BREAKER 4 nili BLUE L2115S50 Parts list for MODEL 16510 TYPE 48EL20 8ET 100 125 or 200 250 VAC 50 60 Hz OTY DESCRIPTION CASE ASSEMBLY TRANSFORMER ASSEMBLY AMMETER ELECTRONIC TIMER ASSEMBLY SHUNT ASSEMBLY HEATSINK ASSEMBLY W SCR CONTROL CABLE ASSEMBLY BUSHING INSULATOR 7W 2 FOR AC CORDSET BUSHING INSULATOR 8P 2 FOR DC CORDSET CORDSET AC 14 3 W PLUG CORDSET 1 5mm HARMONIZED NO PLUG CORDSET DC SY120 PLUG GRAY CORDSET DC LESTER PLUG GRAY CORDSET DC NO PLUG FUSEHOLDER FUSE 15 AMP MDA 15 SWITCH ROCKER DPDT CIRCUIT BREAKER 40 AMP ND NO mm 63 BLUE NATURAL 100 125 200 250 V BLACK 1 BLACK 245 26 I AC 25 BROWN E 3 a 2 2 1 15 BROWN NON K 9 gt o 12 FUSE POLES 413 amp 426 ON RASE SWITCH MOUNT IO THE 4 GROUND PART NO 211498 159458 163095 165955 186965 212495 211525 020285 020085 211475 252485 281135 290525 211465 053225 164995 175585 213338 SETTING SHOWN Spare Parts DELTA Q HF CHARGER NO PART NO DESCRIPTION 1 3102240002 24V CHARGER U S BATTERY 3102240003 24V CHARGER LIFELINE BATTERY 3102302001 36V CHARGER U S BATTERY 3102302002 36V CHARGER LIFELINE BATTER
25. 6 2450007 N A N A 2450008 MOTOR AND DRIVE D00 SEPEX 63 SEPEX DANA DRIVE fy TTE NIA A 2 FO RI SE Ui 0 A 4 eK Dy in My SX ESS 48 COMMON PARTS PART RE DESCRIPTION F 3651003 10 BEARING 3651005 11 SNAP RING 4851001 12 NUT WASHER PACK 6622006 2154660001 15 WAVY WASHER 2154660009 19 HEADBAND 2152002 EE HEADBAND KIT 484001 SPECIFIC 489 98 400 484000 204050 2950002 2450003 3112210001 484010 484010 2450006 6 2450006 484011 484011 2450007 2450007 2450007 484017 484017 N A N A N A 484009 484009 N A N A N A N A N A 2450008 2450008 3112210004 Spare Parts NN 27777222262 2 25 DESCRIPTION PULLEY 22 TEETH PULLEY 25 TEETH BELT EAGLE 1 MOTOR BELT EAGLE 2 MOTOR MOTOR BASE 1 MOTOR MOTOR BASE 2 MOTOR BELT TENSONER SEAL DESCRIPTION MOTOR ASS Y BRUSH SPRING BRUSH PLATE LEAD ASSY BRUSH LEAD AND BRUSH ASSY REF REF 13 14 16 17 18 DANA DIFFERENTIEL 12 DANA DIFFERENTIEL E 322 amp E 330 FORD DIFFERENTIEL GM DIFFERENTIEL 49 REAR SUSPENSION AND BRAKE Spare Parts 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
26. 67 4067 AK 4067 AL 4200 4204 4204 E 4211 A 4215 4216 4221 B 4222 A 4228 4228 A 4230 4230 A D9AZ D9AZ D9AZ D9AZ D9AZ E7TZ E7TZ E7TZ 7 D9AZ E7TZ E7TZ PART NUMBER C7AZ 4628 A C7AZ 4630 4662 4663 0542 4670 E5DZ 4676 4851 ETUZ 4851 389546 S 100 MM 170 A 4859 E6TZ 4859 FORD WEC NON LOCKING REAR AXLE SERVICE PARTS QTY 1 1 1 1 1 Plug housing 1 2 14 Cover assy housing also serviced in assy aroup 4010 Gasket cover to housing use D6AZ 19562 B Shim differential bearing adjustment 241 thick 243 thick 245 thick 247 thick 249 thick 25 thick 253 thick 255 thick 257 thick 259 thick 261 thick 263 thick 265 thick 267 thick 269 thick 271 thick 273 thick 275 thick 277 thick 279 thick 281 thick 283 thick 285 thick 287 thick 289 thick 291 thick 293 thick 295 thick 297 thick DESCRIPTION NON LOCKING REAR AXLE SERVICE PARTS LIST NO 237 Cont d Gear kit differential side use with axle 87206 7245 7300 7 Consists of 2 712 4228 A Washer 2 ETTW 4236 Gear U washer axle shaft retaining Pin differential pinion shaft lock 0 ring axle shaft Bolt housing cover self locking 5 16 18 x 5 8 also serviced in assy group 4010 Use with axle 4WEC A B 720C 7245 730D 7608 762T Use with axl
27. 79 Curtis Speed Controller PROGRAMMING PARAMETERS E 290HD E 348 E 480 E 500 E 660 T 248 T 448 WARNING The owner of this vehicle shall ensure that the service technicians are qualified properly trained and obey the safety rules and guidelines in and ANSI B56 regulations and in this manual Before installing and or programming the 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 THRO DEADBAND Thr Neutral deadband 96 of 5kohms pot THROTTLE MAX Thr Input reg d for 100 PWM 5kohm pot M4 BRAKE C L 1 FIELD MAP START Armature current at wich FIELD MAP takes effect amps M1 THRT BRK MODE 1 THROT BRAKING AS OF BRAKE C L 50 3 3 3 3 O1 O1 O 0 0 0 0 0 70 O1 eo FIELD MAP Field Winding Current as of Armature Current 50 CURRENT RATIO CURRENT RATIO FACTOR OF 1 2 8 STATIC RETURN TO OFF SRO TYPE M2 THRT BRK MODE 2 THROT BRAKING AS OF BRAKE C L 50 M3 THRT BRK MODE 3 THROT BRAKING AS OF BRA
28. AC input DC output connector OEM specific w 12AWG wire All models iis Voltage max Vrms Regulato _ Frequency Hz _ Gurrent max Arms 12 104VAC reduced 20 lt 104v EN 60995 11223 arm Current nominal Arms 10A amp 120VAC 5A amp 230VAC S S RN USED ene TT UL1564 2nd Edition Industrial Battery Charger AC Power Factor gt 0 98 at nominal input current CSA C22 2 No 107 2 Battery Chargers Industrial ___ Unintentional Radiators Class A FCC Part 15 ICES 003 A F ss A Radio disturbance characteristics Class A 55011 LED Active Flash YELLOW Solid YELLOW Flash YELLOW EN 61000 3 2 Limits for harmonic current emissions eis Flash Bargraph Flash YELLOW EN 61000 3 3 Limits of voltage fluctuations and flicker gt 80 Charge Indicator Short Flash GREEN 200 4 Charge Long Fes GREEN _ EN 61000 4 2 Electrostatic discharge immunity 100 Charge Indicator Solid GREEN Solid GREEN En 61000 4 3 Radiated radio frequency EMF immunity Faut Indicator __________ 6100044 Electrical fast ransienvburst immunity _ DCAmmeter LED Bargraph 610045 Surgeimmunity Bat Temp Compensation Automatic Optional _ 61000 4 6 mmu Maintenance Mode Auto restart if V lt 2 1Vpc or 30 days elapse EN 61000 4 11 Voltage variations immunit
29. DC ACCESSORIES DC DC CONVERTER Spare Parts 59 OLA a BLK I0AWG 05 OV HOOTHSLNI 9 HILVIH SYIHSYTH SNOLLdO d3AOMddv 1 SoHinv 91 80 2002 SNOILdO OV HOOTYALNI YILVIH SYUIHSVTH SNOILdO 193rans 8 ISH YATIONLNOO OL BLK RE RED BLK 4 gt ata 8 23 YOLOVLNOO LIN T 5 is T 5 5 148 5 E 62X Y LS LM 94 OPTIONS Spare Parts PARTS LIST 246108K GI BATTERY PG G2 BATTERYCHARGER 1 RELAY BASE l2466 ___ 1 RELAY RETAINING CLIP 246216C I M2 SEPEXMOTOR 1 M3 SERIESMOTOR 1 MICROSWITCH 02 1 POTENTIOMETER 36703 1 PLASTICGEAR 305 1 SPRING 2462008 246205 LIGHTSWITCH PUSHPULL 46002 1 HYDRAULIC BRAKE LIGHT SWITCH 36004 1 EMERGENCY PUSH BUTTON LABEL 310980006 DC DC CONVERTER l XI HOUR METER CONNECTOR X2 SPEED CONTROL CONNECTOR X4 _____ SPEED CONTROL CONNECTOR j X5 ____ BATTERY CHARGER CONNECTOR 1 1 48VOLTMAINCONTACTOR 486222 1 48 VOLTHR CONTACTOR 486217 2 FIRBUSSBARS 246008 __ 1 STATICSTRAP 4001 __ 1 Consult Motrec Illustrated parts 60 Spare Parts Spare Parts BATTERY CONFIGURATIONS 48V CONF
30. ERY 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 1s adjustable via potentiometer M on the rear A B D JF 1 68 1 93 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 80 of the battery capacity The recommended setting for 6V batteries 1s 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 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 1s turned on When it 18 down to 0 the display flashes After the maintenance reset the counter depress the button R on the rear The service counter is fa
31. IGURATIONS DES BATTERIES 48V 48V 12V Accessories Ground ll A H ibis off b 48V 12V Accessories Ground E 480 o EE 12V Accessories p E 660 Ground 0 djih H 0 6 E 348 61 BUILT IN PORTABLE 25 CHARGER CAPACITOR N 09 ELECTRONIC TAN TIMER KIT HEATSINK ASSEMBLY WITH DICOES 5 TAN M QC C E 45 WHITE OR RED C OC COROSET _ BLACK 2 ro BLACK 2 ro 2 BATTERIES TRANSFORMER TAN WHITE FUSE AMMETER ASSEMBLY CASE GROUND Parts list for LESTRONIC II charger MODEL 09695 TYPE 48LC25 8ET 115 VAC 60 Hz PART NO DESCRIPTION 097275 CASE ASSEMBLY 096965 TRANSFORMER ASSEMBLY 163548 HEATSINK ASSEMBLY WITH DIODES 041278 AMMETER 096648 ELECTRONIC TIMER ASSEMBLY RELAY 037355 023908 CAPACITOR 6 0 MFD 660 VAC 087768 FUSE ASSEMBLY 020288 BUSHING 7W 2 INSULATOR FOR CORDSETS 025068 CORDSET AC 085125 CORDSET DC NO PLUG 149738 CORDSET DC WITH SILICONE PLUG 8020S CORDSET DC WITH LESTER PLUG 086078 CORDSET DC WITH 50 AMP ANDERSON PLUG 105368 CORDSET DC WITH 50 AMP EZ GO PLUG 082248 CORDSET DC WITH 175 AMP ANDERSON PLUG 083135 PLUG ASSY DC 50 AMP ANDERSON PLUG 029575 PLUG 55 DC 175 AMP ANDERSON PLUG 1 Spare Parts AC INPUT GROUNDED PLUG AC CORDSET BUILT IN PORTABLE CHARGER MODEL 165
32. KE C L 50 TAPER RATE ipd brak Decrease rate when apporch Ospd M1 MAX SPEED MODE 1 MAX SPEED AS PWM OUTPUT 4 0 2 EM BRAKE ELECTROMAGNETIC BRAKE ON OR OFF AUX DELAY AUXILIARY DRIVER DROPOUT DELAY IN SEC AUX CHECK AUXILIARY COIL OPEN CHECK ON OR OFF EM BRAKE DELAY ELECTROMAGNETIC BRAKE DELAY IN SEC EM BRAKE CHECK ELECTROMAG BRAKE OPEN CHECK ON OR OFF 32 0 O O O M2 MAX SPEED MODE 2 MAX SPEED AS PWM OUTPUT O O M3 MAX SPEED MODE 3 MAX SPEED AS PWM OUTPUT e eo M4 MAX SPEED MODE 4 MAX SPEED AS PWM OUTPUT M1 CREEP SPEED MODE 1 CREEP SPEED AS PWM OUTPUT M2 CREEP SPEED MODE 2 CREEP SPEED AS PWM OUTPUT 0 CREEP SPEED MODE 3 CREEP SPEED AS PWM OUTPUT M4 CREEP SPEED MODE 4 CREEP SPEED AS PWM OUTPUT O REGEN SPEED Min speed for regen braking as of vehicle speed O CTRL MODE CONTROL MODE THROTTLE TYPE THROTTLE TYPE N O F F F F F F 50 F F F N F F F F F F F F F CD e eo 29 Curtis Speed Controller CURTIS PMC MOTOR CONTROLLER 30 MANUAL CURTIS 1204X 1205X and 1209 1221 MOTOR CONTROLLERS 1999 CURTIS INSTRUMENTS INC DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 1204X 1205X 1209 1221 Manual p n 98796 Rev May 1999 31 OVERVIEW OVERVIEW Curtis PMC Model 1204X 1205X
33. TER 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 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 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 sw
34. VR OC cont driver output overcurrent 1 Contactor coil shorted MAIN CONT WELDED welded main contactor Main contactor stuck closed Main contactor driver shorted PRECHARGE FAULT internal voltage too low at startup 1 Controller defective 2 External short or leakage path to B on external B connection MISSING CONTACTOR missing contactor Any contactor coil open or not connected MAIN CONT DNC main contactor did not close Main contactor missing or wire to coil open LOW BATTERY VOLTAGE low battery voltage Battery voltage undervoltage cutback limit Corroded battery terminal Loose battery or controller terminal OVERVOLTAGE overvoltage Battery voltage overvoltage shutdown limit Vehicle operating with charger attached Battery disconnected during regen braking THERMAL CUTBACK over under temp cutback Temperature gt 85 C or gt 25 C Excessive load on vehicle Improper mounting of controller Operation in extreme environments ANTI TI EDOWN Mode 2 or Mode 4 selected at Mode switches shorted to B startup 2 Mode switches tied down to select Mode 2 or Mode 4 permanently Curtis PMC 1244 Manual 27 78 8 DIAGNOSTICS 8 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 LED displays fault codes
35. Y 3102480002 48V CHARGER U S BATTERY 3102480003 48V CHARGER LIFELINE BATTERY 2 3119000011 CONNECTOR C13 64 Tel 604 327 8244 Fax 604 327 6 Unit 3 5250 Grimmer St Burnaby BC Canada V5H 2H2 INFORMATIONS IMPORTANTES DE SECURITE Conserver ces instructions Ce manuel contient des instructions importantes concernant la s curit et le fonctionnement Information de S curit de la Batterie www deita q com 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 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 desassembl
36. Y THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY e tis 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 OSHA and ASME ANSI B56 8 amp 256 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 e not drive 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 Do not open 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 e not exceed the vehicle carg
37. a 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 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 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 ANSI B56 Do not drive this vehicle unless you are a certified operator as required by 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 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 15 fully charged To interrupt the charging cycle discon
38. battery 1116 and the number 01 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 15 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 Let the battery warm up before charging Charge batteries in stored vehicles every month DEFECTIVE BATTERY Check specific gravity of each cell if a cell 15 shorted voltage drop may occur only when there 15 current 17 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 REGIS
39. ch means the problem is either in the forward switch or the switch wiring STEP 4 Check or replace 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 Curtis PMC 1244 Manual 26 LJ 8 DIAGNOSTICS amp TROUBLESHOOTING Table5 TROUBLESHOOTING CHART PROGRAMMER FAULT LCD DISPLAY CATEGORY EXPLANATION POSSIBLE CAUSE HW FAILSAFE1 2 3 1 self test or watchdog fault Controller defective M SHORTED 1 internal M short to B Controller defective FIELD OPEN 1 field winding fault Motor field wiring loose 2 Motor field winding open ARM SENSOR armature current sensor fault Controller defective FLD SENSOR field current sensor fault Controller defective THROTTLE FAULT 1 wiper signal out of range Throttle input wire open Throttle input wire shorted to B or B THROTTLE FAULT 2 pot low fault Throttle pot defective 2 Wrong throttle type selected SRO SRO fault Improper sequence of KSI interlock and direction inputs Wrong SRO type selected Interlock or direction switch circuit open Sequencing delay too short HPD fault Improper seq of direction and throttle inputs Wrong HPD type selected Misadjusted throttle pot Sequencing delay too short BB WIRING CHECK emergency reverse wiring fault Emergency reverse wire open 2 Emergency reverse check wire open CONT DR
40. cing 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 15 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 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
41. complete diagnostic information in plain language Faults are displayed in the Diagnostic Menu see 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 is 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 STEP3 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 whi
42. ctory programmable only 24V UNIT 2469026 36V UNIT t 3069038 48V UNIT 4869037 2 Orange key switch 3 Relay 4 Relay 5 Black battery 6 Blue hour counter 8 White battery 69 Addendum ADDENDUM 70 Addendum CURTIS FOOT PEDAL BLUE KEY SWITCH GREEN HOUR METER BLACK POTENTIOMETER WHITE POTENTIOMETER REF PART NO DESCRIPTION 306200165 ACCELERATOR CURTIS 367008 POTENTIOMETER 2262004C SPRING 22620016 MICRO SWITCH 22620036 LEVER 3662002 CABLE PROTECTOR RESP CLAUDE L MODEL E E 320 360 480 500 NO 321A320001 SER 1018799 TO 1019973 OV NM 71
43. drogen gas which can build up in and around the batteries Follow the battery manufacturer s safety recommendations Wear safety glasses Curtis PMC 1204X 1205X 1209 1221 Manual 33 2 WIRING WIRING CONNECTIONS Low Current Two 1 4 push on terminals are provided for the throttle inputs If your controller has a voltage throttle input there will be only one throttle terminal A 6 pin low power connector molded into the right side of the controller face provides the low power logic control connections KSI input forward reverse contactor output bypass contactor output optional emergency reverse optional and forward and reverse inputs Keyswitch input KSI Throttle inputs B F R contactor output Bypass contactor output Emergency reverse input Forward input Reverse input Several manufacturers make mating connectors that fit this connector The part numbers listed are for the recommended 0 75 mm 18 AWG vinyl insulated stranded wire MFR PART NUMBER DESCRIPTION AMP 640426 7 locking insulation displacement terminals wires at right angle to connector Methode 3300 107 218 locking insulation displacement terminals Molex 09 50 3071 locking crimp terminals Panduit CE156F18 7 locking insulation displacement terminals wires at right angle to connector Curtis PMC 1204X 1205X 1209 1221 Manual 34 11 WIRING CONNECTIONS High Current Four tin plated solid copper bu
44. e 87800 762 Stud housing 00 8 5 16 18 and 5 16 18 x 1 1 2 long also serviced in assy group 4010 u5e with axle 7600 762P Guo driving pinion bearing front 8 88048 Cone and roller drive pinion front bearing 41100 n42 44 373098 5100 PP 42 B 342 4033 4036 4067 DIAZ 4067 092057 38 092 0 DSAZ 4067 D D9AZ 4067 0942 4067 F D9AZ 4067 G D9AZ 4067 D9AZ 4067 J D9AZ 4067 K D9AZ 4067 L DOAZ 4067 D9AZ 4067 N D9AZ 4067 P 0922 4067 R 094575 58 0942 4067 0922 4067 U 092 4067 V D9AZ 4067 W D9AZ 4067 D9AZ 4067 D9AZ 4067 7 D9AZ 4067 DIAZ 4067 D9AZ 4067 0942 4067 AD D9AZ 4067 0922 4067 PART NUMBER FORD WEC E7TZ 4236 C7AZ 4N237 0882 4241 0722 4 332 4346 E6TZ 4346 E6TZ 4346 ESTZ 4346 4616 A 4621 Spare Parts OTY N 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 BRAKE CONTROLS REF PART NO 2190000003 2910000013 2139240002 2129000003 2129000001 2921000001 2127000006 2127000001 2191240002 14 15 16 17 18 19 20 21 22 23 24 25 45 OTY DESCRIPTION Nut 1 4 20UNC Yoke
45. e 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 To check change the charging algorithm above open areas or areas with cut outs for airflow is desirable a Disconnect the charger positive P Battery Type Concorde 2xxAh AGM 27 Contact Delta Q for information on other mounting orientations As the charger may get hot in operation the charger must be connector trom battery pack Apply AC power and after the LED test the installed such that risk of contact by people is reduced The 4 charger s AC plug must be located at least 18 above the floor Algorithm will display for 11 seconds Crown LS a round surface and the status display must be visible to the user b To change algorithm touch positive ne 9 pray connector during the 11 second display generic flooded CP dv dt 2 Mounting Procedure period to the battery pack s positive 8 Concorde 1xxAh AGM Mount the charger by the mounting plate using appropriate terminal for 3 seconds and then remove Trojan 1305 1 fasteners i e 1 4 or M6 with locking hardware For UL2202 the Algorithm will advance after 3 EN DEKA 8031 Gel compliance a 12AWG green bonding wire with
46. ed 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 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 2 Make sure charger connections to battery terminals are tight and clean 3 Donotexpose charger to oil dirt mud or to direct heavy water spraying when cleaning vehicle m See flip side for Product Specifications and Installation Instructions for qualified personnel 65 Spare Parts Specifications QuiQ Model 912 _ Voltage nom V Mechanical Al models Dimensions 28 0 x 24 5 x 11 0 cm 11x 9 7 x 4 3 Voltage max V Weight gt lt 5 kg 11 Ibs w standard output cord Current max A Environmental Enclosure 46 aatar Tyna Operating 30 C to 50 C 22 F to 122 F derated Electronic rotection auto reset Temperature PUR pm above 30 C below 0 nd Storage Temperature 40 C to 70 C 40 F to 158 F Short Circuit Electronic current limit AC input connector IEC320 C14 require 21 8m localized cord
47. ed to neutral before output is allowed optional feature v Emergency reverse enhances plugging current when belly button is acti vated on walkie type applications optional feature K Delayed bypass 1A output drives a bypass contactor optional feature v Forward reverse and bypass contactor driver outputs are internally pro tected against shorts in the contactor coils K Simple installation with no adjustments required V Tin plated solid copper bus bars v Push on connectors for control wiring Familiarity with your Curtis PMC controller will help you to install and operate it properly We encourage you to read this manual carefully If you have questions please contact the Curtis office nearest you Working on electric vehicles is potentially dangerous You should protect yourself against runaways high current arcs and outgassing from lead acid batteries RUNAWAYS Some fault conditions could cause the vehicle to run out of control Jack up the vehicle and get the drive wheels off the ground before attempting these procedures or any other work on the motor control circuitry HIGH CURRENT ARCS Electric vehicle batteries can supply very high power and arcs can occur if they are short circuited Always open the battery circuit before working on the motor control circuit Wear safety glasses and use properly insulated tools to prevent shorts LEAD ACID BATTERIES Charging or discharging generates hy
48. 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 POINTS TENSIONING Check the force F required to provide a deflection of 1 8 in If the measured force 18 less than 15 Ibs then lengthen centre distance C P SPAN LENGTH D DIAMETER IN d DIAMETER IN R PONGE que q DEFLECTION INJ C CENTER DISTANCE IN 13 Maintenance HYDRAULIC BRAKES DRUM BRAKES Remove brake drums and check linings wear the linings should have a 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 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 rea
49. er le chargeur referer toute reparations aux personnes qualifi s Pas l usage des enfants Product Manual for QuiQ 912 24xx 36xx 48xx 72xx Spare Parts HFIPFC Battery Charger QuiQ SAVE THESE IMPORTANT SAFETY INSTRUCTIONS This manual contains important safety operating and 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 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
50. es have been fully charged WARNING DECALS amp MARKINGS X PES 41 _ _ SEALED CONTROL BOX STATIC STRAP MASTER CYLINDER FLUID DOT3 X 2 50 mm maximun travel STEERING FOR PLAY X J emes om X gt reguires 10 Ibs 5 kg force to apply 10 Ibs 5kg force for 1 8 3mm deflexion X pulleys alignment see procedure oo X Jr CLEAN TIGHTEN WIRE TERMINALS WASH BATTERY TOP WITH WATER I O j MOTOR BRUSHES FOR WEAR X ACCELERATOR ADJUSTMENT 1 8 3 mm travel to activate micro switch X 0 to 50 ohms when micro switch activated 4500 to 5500 ohms with pedal down E TEISE 2 HYDR BRAKE LINES FOR LEAK oll X a for wear play 1 16 1 5 mm minimum lining thickness LUBRICATE brake pedal pivots steering column ball px joints and kingpins Before adding oil check oil seals for leaks FRONT WHEEL BEARINGSPLAY X TIGHTEN NUTS BOLTS electric terminals drive steering brakes suspension body X REPLACE DIFFERENTIAL OIL SAE 30 0060000000 CLEAN AND RE PACK FRONT HUBS __ T dq X J SERVICE DIFFERENTIAL replace the three oil seals 00 0 00 0 00 x wheel bearings oil SAE 30 Iw gt 11 Maintenance ACCELERATOR GEAR Remove the c
51. he 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 1s defective the PMC must be replaced Check the Motor First disconnect battery B and B disconnect power terminals and check the motor armature and field for opens 21 Curtis Speed Controller CURTIS SPEED CONTROLLER 222 MANUAL CURTIS FC 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 521 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 12 914 666 2971 Fax 914 666 2188 CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE CALIFORNIA 94550 USA 17 925 961 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 24 2 INSTALLATION amp WIRING Controller
52. 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 3 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 This 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 accept
53. ious interlocks The controller KSI is used to turn the controller on and off KSI is turned on by connecting it to battery B Any positive voltage greater than about 8 volts will turn on the controller but usually the full vehicle battery voltage Is used In its simplest form KSI is operated by a keyswitch that turns the vehicle off and prevents unauthorized use The keyswitch should also turn off the main Curtis PMC 1204X 1205X 1209 1221 Manual 35 12 WIRING L j CONTEA KEYSWITCH INTERLOCKS TUN not used with SRO controllers gt sgio e O POLARITY POWER WIRING PIODE FUSE MAIN PRECHARGE RESISTOR 250 Q 5 W A N _ Ta 7 0 N lt lt POTBOX gt F R 5 r 1 1 52 L KSI 8 F R cont out Din Bypass cont output i Emergency reverse E EWD input NN L REV input 1A BYPASS See Figure 10 for emergency reverse Fig 8 Basic wiring configuration Curtis PMC 1204X 1205X 1209 1221 controllers contactor and the forward reverse contactors This will act as a safety feature by removing power from the motor control system when the keyswitch is off Interlocks seat switches battery charger interlocks etc should be wired in series so that they turn off the controller KSI and the contactors An SRO interlock a seat switch for example must be wired in order to implement the optional SRO feature
54. itches 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 B 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 B check wiring Turn the key switch ON check voltage between output terminal on the key switch and the terminal on the battery gage 1f 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 bad reverse contactor 15 the most probable cause of the problem Switch to reverse
55. l 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 hazard The d
56. nect 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 instructions 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 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 all switches set the F R selector to neutral set the parking brake remove the key before leaving the vehicle 6 Maintenance MAINTENANCE Maintenance SAFETY WARNINGS FOR
57. not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow N been dropped or otherwise damaged in any way refer all repair work to qualified personnel Not for use by children Operating Instructions 1 Always use a grounded outlet When using an extension cord avoid excessive voltage drops by using a grounded 3 wire 12 AWG cord 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 and 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 plugaed 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 3 Once a minimum battery voltage is detected the charger will enter the bulk charging constant current stage Models 912 xx0x 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 tem
58. o 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 that 15 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 Keepto 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 are
59. ollowing adjustment procedure The keyswitch should be off during adjustment 1 Remove the socket head screw 1 8 Allen for the adjustment you want to make 2 Adjust the internal potentiometer using a small insulated screwdriver available from Curtis 3 Replace the socket head screw and nylon seal washer To prevent stripping do not over tighten POTBOX Maintenance Potbox maintenance is similar to controller maintenance inspect for integrity of connections and mounting and clean with a moist rag as required Adjustment Curtis PMC potboxes are factory set and rarely require user attention To test and adjust connect an ohmmeter to the potbox wires and use this procedure 1 With the spring holding the lever arm against the return stop the resistance should be less than 50 ohms Slowly move the lever If the resistance abruptly starts to increase when the lever is 3 mm 1 8 from the stop 1 5 mm 1 16 for potboxes without the microswitch no adjustment is needed Curtis PMC 1204X 1205X 1209 1221 Manual 38 23 MAINTENANCE 8 ADJUSTMENT 2 If adjustment is required loosen the screw holding the lever on the pot shaft Use a screwdriver to rotate the pot shaft slightly with respect to the lever Recheck the point at which the resistance starts to increase and continue making adjustments until the increase starts at 3 mm 1
60. over Backlash between gears must be reduced to a minimum by sliding holder use locktite 2 to lock the three screws When the plastic gear 1s fully depressed a small backlash must remain between the gears When the plastic gear 18 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 PMC 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 To 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 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 E ADJUSTING SCREW ACTUATOR PIN 12 Maintenance BELT INSTALLATION AND TENSIONING INSTALLATION Adjust the sprockets using a straight
61. peratures 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 xxOx AC LED and Models 912 xx1x 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 4 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 xx0x turn on the 80 LED and Models 912 xx1x will flash 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 5 Alow current finish charae phase is next applied to return and maintain maximum battery capacity Models 912 xx0x will flash the 100 LED 6 When Models 912 xxOx 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
62. r 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 1 2 18 2 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 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 The 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 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
63. ring terminals seconds Repeat until desired Algorithm 5 Trojan 30XHS must be attached from the bonding stud located on the front of the is displayed A 30 second timeout is 4 US Battery US2200 charger identified by to the vehicle frame The vehicle extended for every increment Trojan T 105 connection must be made using corrosion resistant hardware Incrementing beyond the last Algorithm Table 1 e g a 10 stainless steel machine screw with at least two moves back to the first Algorithm threads of engagement and if required a paint piercing washer After desired Algorithm is displayed touch the charger connector to the battery positive until the output relay is 3 DC Battery Connection Procedure heard to click 10 seconds algorithm is now in permanent memory The green wire outputs battery voltage when the charger is not Remove AC power from the charger and reconnect the charger positive plugged into AC to provide an interlock function see Fig 1 If connector to the battery pack It is highly recommended to check a newly used a user supplied 1A fast blow external fuse must be changed algorithm by repeating step 4 above installed inline to prevent damage Shorting or drawing more than 1A may damage charger and void the warranty Product warranty is two years please contact dealer of original equipment for warranty b Securely fasten the black ring terminal from the charger to the service negative terminal
64. river 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 28 08 2007 Og O 10 12 13 14 15 16 18 19 22 25 26 27
65. s bars are provided for the high current connec tions to the battery and motor Negative connection to battery Positive connection to battery and to motor armature Output to motor field Plug diode to motor armature The cables used for the battery and motor connections must be heavy enough to carry the high current required Rubber insulated welding cable is convenient to work with because of its flexibility Connections to the controller bus bars should be made with lugs suitable for the cable used fastened by M8 5 16 bolts and nuts When tightening the bolts two opposing wrenches should be used Failure to use the double wrench technique could cause undue strain to be placed on the internal connec tions and could also result in cracked seals around the bus bars WIRING TYPICAL INSTALLATION Curtis PMC 1204X 1205X 1209 1221 controllers are designed to satisfy the requirements of material handling applications using series motors Figure 8 isa schematic diagram of the installation shown in Figure 7 Wired this way the vehicle will plug brake if the direction 15 changed with the vehicle moving and the throttle applied Reversing is accomplished via a forward reverse changeover contactor or two single pole double throw 2xSPDT contactors Coil suppres sion diodes should be used on the main and forward reverse contactors KSI Wiring The keyswitch input KSI circuit includes inputs from the keyswitch and from the var
66. surface 18 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 11 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 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 t
67. ty 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 any cell to avoid electrolyte to be forced out while charging Fill each cell to plate level with distillated or de 10nized water before battery charging When the battery 18 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 216 Maintenance BATTERY MOUNTING A loose battery increases damaging effects of vibrations and 1s more prone to short out BATTERY DISCHARGE LIMIT Discharging below a 20 state of charge cuts down the
68. wo opposing wrenches This double wrench technique will help avoid putting stress on the bus bars which could crack the seals Always use insulated wrenches 2 Inspect all seals at the front and back of the controller If necessary use a moist rag to wipe these areas clean enough so that you can see the seals Look for cracks and other signs of seal damage If the seals are intact clean the controller thoroughly either by washing it off or by wiping it clean with a moist rag Power must not be reapplied until the controller terminal area is completely dry If the seals have been damaged there are several possible causes Perhaps the double wrench technique was not used when the cables were installed Perhaps the vehicle s environment requires that the controller be better protected either by mounting it in a different location or by installing a protective cover Damaged seals can lead to faulty operation We strongly recom mend replacing controllers that have faulty seals Adjustment Some controllers allow adjustment of the plug braking current current limit and acceleration rate settings The adjustment pots on these models are located as shown in Figure 16 Curtis PMC 1204X 1205X 1209 1221 Manual 37 22 MAINTENANCE 8 ADJUSTMENT Fig 16 Adjustment pots CURRENT LIMIT ADJUST CCW lower current limit PLUG CURRENT ADJUST ACCELERATION RATE ADJUST CW higher plug current CW faster acceleration Use the f
69. y 1A Installation Instructions AN WARNING The output of chargers with greater than 48V may Charger pose an energy and or shock hazard under normal use These Internal NO units must be installed in the host eguipment in such a Output O manner that the output cable and battery connections are only accessible with the use of a tool by qualified personnel Interlock Be BLKWHT B 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 nat 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 tis 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 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 b

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