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MAINTENANCE MANUAL

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1. E 290HD OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1038265 amp UP Printed in Canada One Year Limited Warranty Effective April 25 2005 Inc hereby warrants to the Original Retail Purchaser Owner that any of its vehicles shall be free from any defect in materials for a period of 90 DAYS while in the possession of such Original Retail Purchaser This warranty IS NOT TRANSFERABLE to any subsequent Buyer The warranty period is extended to one year or one thousand 1 000 hours which ever first occurs on the electric motor differential parts that bathe in oil and the electronic speed controller 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 responsibilit
2. 1 Determine Mounting Location While its sealed nature allows the charger to be mounted virtually anywhere the choice of mounting location and orientation is extremely important For optimum performance and shortest charge times mount the charger in an area with adequate ventilation The charger should also be mounted in an area that will be relatively free of oil dirt mud or dust since accumulations within the fins of the charger will reduce their heat dissipating qualities Optimal cooling also occurs when the charger is mounted on a horizontal surface with the fins vertical More airflow from below the charger will help cool the fins so mounting above open areas or areas with cut outs for airflow is desirable Contact Delta Q for information on other mounting orientations As the charger may get hot in operation the charger must be installed such that risk of contact by people is reduced The charger s AC plug must be located at least 18 above the floor ground surface and the status display must be visible to the user 2 Mounting Procedure Mount the charger by the mounting plate using appropriate fasteners i e 1 4 or M6 with locking hardware For UL2202 compliance a 12AWG green bonding wire with ring terminals must be attached from the bonding stud located on the front of the charger identified by to the vehicle frame The vehicle connection must be made using corrosion resistant hardware e g a 10 stai
3. CSA ISEILEIHL OOV 9NIMVHG ddAOHddv NONSVO f UoHinv c V v0 900c 31va H3lH3ANOO 8910553997 LO NOISH3A ISL TILL THI S3IHOSS32OV 5 QSULOW X18 gt RED BLK a m WHT gt ee tV I ee ee g a a a at RED WHT OLS ie 4 e m WHT gt 2 1 q lt 39 Spare Parts PARTS LIST B B E E FU F m o FLA CIRCUIT BREAKER 150A 3107000002 1 DIODES 867012 3 F BATTERY _____ SEEXMOTIOR SERIES MOTOR SPRING 2462008 2 3 1 2 B 3 B 5 GI G2 2 M3 1 1 4 S S15 1 1 2 5 Un a Z Q R R unu un 92 510 HORN BUTTON l 512 DC DC CONVERTER HOUR METER CONNECIOR SPEED CONTROLCONNECTOR BATTERY CHARGER CONNECTOR 2 2 2 ERBUSSBARS 124690031 STATICSTRAP 12450001 p U X X X 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Consult Motrec Illustrated parts 40 Spare Parts AG INPUT GROUNDED PLUG AC CORDSET CASE GROUND BUILT IN PORTABLE 25 CHARGER CAPACITOR N 99 ELECTRONIC TAN TIMEA KIT HEATSINK ASSEMBLY WITH DICOES B TAN C M QC C E 45 WHITE OR RED C
4. BATTERY MAINTENANCE WARNING It is the responsibility of the owner of this vehicle to ensure that the service technicians are properly trained read and obey the safety rules and guidelines in this manual ANSI 56 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 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
5. terminal on the battery gage check voltage between the reverse terminal and the terminal on the battery gage if both B replace the F R switch Check switches and wiring Disconnect control terminals on the PMC and check all control signals If a switch pin does not read B check wiring or replace the switch Check potentiometer Turn the key switch to OFF disconnect potentiometer terminals Check the resistance across terminals if not within the recommended limits adjust or replace the potentiometer Check for shorts between potentiometer wires and vehicle frame resistance should read at least 1 megohm 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 B and B then PMC B and M Check the internal diod
6. 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 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 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 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 a well ventilated area set for and approved for charging Never lea
7. 5 GREEN x 92 _ hu 9 GROUND BLUE L2115S50 Parts list for MODEL 16510 TYPE 48EL20 8ET 100 125 or 200 250 VAC 50 60 Hz PART NO DESCRIPTION 211495 1 ASSEMBLY 159455 1 ASSEMBLY 163695 1 165955 1 ELECTRONIC TIMER ASSEMBLY 186965 1 SHUNT ASSEMBLY 21249S 2 HEATSINK ASSEMBLY W SCR 211525 1 CONTROL CABLE ASSEMBLY 02028S BUSHING INSULATOR 7W 2 FOR AC CORDSET 02008S BUSHING INSULATOR 8P 2 FOR DC CORDSET 21147S CORDSET AC 14 3 W PLUG 252485 1 CORDSET 1 5mm HARMONIZED NO PLUG 261135 1 CORDSET DC SY120 PLUG GRAY 290525 1 CORDSET DC LESTER PLUG GRAY 211465 1 CORDSET DC NO PLUG 05322S 1 FUSEHOLDER 164995 2 FUSE 15 AMP MDA 15 175565 1 SWITCH ROCKER DPDT 21333S CIRCUIT BREAKER 40 AMP 42 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 BATTERY 3102480002 48V CHARGER U S BATTERY 3102480003 48V CHARGER LIFELINE BATTERY 2 3119000011 CONNECTOR C13 43 Spare Parts QuiQ HFIPFC Battery Charger SAVE THESE IMPORTANT A 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 syste
8. Regulato EN 60335 1 2 29 Safety of Appliances Battery Chargers UL2202 EV Charging System Equipment UL1564 2nd Edition Industrial Battery Charger CSA C22 2 107 2 Battery Chargers Industrial FCC Part 15 ICES 003 Unintentional Radiators Class A B EN 55011 Radio disturbance characteristics Class AEON Flash YELLOW EN 61000 3 2 Limits for harmonic current emissions ene aes Flash Bargraph Flasn YELLOW EN 61000 3 3 Limits of voltage fluctuations and flicker lt 80 Charge Indicator Short Flash GREEN _ gt 80 Charge Indicator Solid YELLOW Long Flash GREEN _ EN 61000 4 2 Electrostatic discharge immunity 199 Charge diemor SOPI GREEN 61000 4 3 Radiated radio frequency EMF immunity WA ENG10004 4 Electrical fast transient burst immunity JD MIT rro LED Hargraph 61000 4 5 Surge immunity Bat Temp Automatic Optional 61000 4 6 Gonducied immunity Maintenance Mode Auto restart if V lt 2 1Vpc or 30 days elapse EN 61000 4 11 Voltage variations immunity Installation Instructions WARNING output chargers with greater than 48 pose energy and or shock hazard under normal use These units must be installed in the host equipment in such a manner that the output cable and battery connections are only accessible with the use of a tool by qualified
9. 295 thick 297 thick Gear kit differential side usa with axle 87200 7245 7300 1987 Consists of 2 E7TZ 4228 Washer 9 E7TW 4236 AA Gear U washer axle shaft retaining Pin differential pinion shaft lock ring axle shaft Bolt housing cover self locking 5167 18 x 5 8 serviced in assy group 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 7600 762P Cup driving pinion bearing front 88048 Cone and roller drive pinion front bearing HMB88048 QTY AR AR AR AR AR 233 PART NUMBER FORD NON LOCKING REAR AXLE SERVICE PARTS LIST NO 237 09 2 D9AZ D9AZ D9AZ D9AZ 2 ETTZ 2 0542 0942 712 2772 C7AZ C7AZ B7A D5AZ E5DZ E7UZ 4067 4067 AG 4067 4067 AJ 4067 4067 AL 4200 4204 4204 E 4211 4215 4216 4221 4222 4228 4228 4230 4230 4628 4630 A 4662 A 4663 4670 A 4676 4851 4851 389546 5100 170 E6TZ 4B59 4859 A DESCRIPTION Shim differentia bearing adjustment Cont d 299 thick 301 thick 303 thick 305 thick 4307 thick Differential assy refer to group in Section 40 Case assy differential Use with axle 7200 724S 730D 1987
10. 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 348 E 480 E 500 E 660 T 248 T 448 SPARE PARTS BODY FORD F 150 DIFFERENTIAL BRAKE CONTROLS STEERING MOTOR AND DRIVE ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT ACCESSORIES DC DC CONVERTER BUILT IN PORTABLE 25A CHARGER BUILT IN PORTABLE CHARGER MODEL 16510 DELTA Q HF CHARGER MOTREC ILLUSTRATED ACCESSORIES CONVERTER INSTALLATION BATTERY DISCHARGE INDICATOR HOBBS O k 10 12 13 14 15 16 18 19 22 25 26 27 28 29 30 31 32 34 35 37 36 39 41 42 43 46 48 49 Instructions INSTRUCTIONS Instructions SAFETY WARNINGS FOR OPERATORS e FAILURE TO OBEY 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 ASM
11. 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 DEADMANSWITCH 4 STATIC STRAP min 2 contact with ground X J _ CHECK FILL BATTERIES add distilled water to cover plates Fill to recommended level after batteries have been fully charged p ae _ X EE Rated CABLE PROTECTORS SEALED MOTOR SEALEDOONTROLBOXSTANCSTRAP T MASTER CYLINDER FLUID DOT3 T iuc 2 50 mm maximum travel o E E gt gt lt STEERING FOR PLAY nm md PARKING BRAKE LEVER requ
12. the residual capacity of batteries Operating hours Status of service down counter The residual capacity of the battery 15 monitored 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 jF JG JH J 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 15 down to 0 the display flashes After the maintenance reset the counter depress the button R on the rear The service counter is factory programmable only 24V UNIT 2469026 36V UNIT
13. 3069038 48V UNIT 4869037 2 Orange key switch 3 Relay 4 Relay 5 Black battery 6 Blue hour counter 8 White battery 49
14. 912 xx1x single LED flashes YELLOW When the battery is at approximately 80 state of charge the bulk stage has completed and an gt 80 charge indication is given Models 912 turn on the 80 LED and Models 912 xx1x will fiash its LED GREEN on more than off In the next phase known as the absorption or constant voltage phase the last 20 of charge is then returned to the battery The charging could be terminated at this point if the vehicle requires immediate usage however it is highly recommended to wait until 10096 charge indication is given to ensure maximum battery capacity and life A low current finish charge phase is next applied to return and maintain maximum battery capacity Models 912 xxOx will flash the 100 LED When Models 912 10096 LED or Models 912 xx1x single LED is continuously GREEN the batteries are completely charged The charger may now be unplugged from AC power always pull on plug and not cord to reduce risk of damage to the cord If left plugged in the charger will automatically restart a complete charge cycle if the battery pack voltage drops below a minimum voltage or 30 days has elapsed If a fault occurred anytime during charging a fault indication is given by flashing RED with a code corresponding to the error There are several possible conditions that generate errors Sorne errors are serious and require human intervention to first resolve the problem and then to reset the charger by in
15. OC COROSET _ SLACK 2 ro SLACK 2 ro 2 BATTERIES TRANSFORMER TAN C FUSE ASSEMBLY WHITE Parts list for LESTRONIC II charger MODEL 09695 TYPE 48LC25 8ET 115 VAC 60 Hz PART NO DESCRIPTION 097275 CASE ASSEMBLY 09696S TRANSFORMER ASSEMBLY 16354S HEATSINK ASSEMBLY WITH DIODES 04127S AMMETER 09664S ELECTRONIC TIMER ASSEMBLY RELAY 037355 02390S CAPACITOR 6 0 MFD 660 VAC 08776S 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 55 50 ANDERSON PLUG 02957S PLUG ASSY DC 175 AMP ANDERSON PLUG 41 Spare Parts BUILT IN PORTABLE CHARGER MODEL 16510 100 125 V Jat FUSE 15 TRANSFORMER ys SHUNT DC SCR warp OUTPUT BLACK BLACK oso 26 AC 25 BROWN VOLTS CIRCUIT BR BREAKER INPUT 3 n 2 2 4 WHITE 13 BROWN NN lt 11 E E C SCR 512 2 C 2 BLACK SETTING SHOWN 753 6 F c COE 100 125V t POLES 413 amp 26 ON OLTAGE SWITCH MOUNT TO THE THE BASE OPENING x
16. Shaft differential pinion kit use with axle 7200 7245 7300 1987 Consists of 1 E7TW 4211 Shaft 1 0882 4241 4 Pin Pinion kit use with axle 87200 7245 1300 1987 Consists of 2 4215 Pinion 2 7 2 4230 Washer Bolt differentlal case self locking 7 16 20 x 3 4 Cone and roller differential bearing 8 LM803049 Cup differential bearing LM803012 Washer differential side gear thrust also serviced in kit group 4236 Use with axle 720 7245 7300 1987 Washer differential pinion thrust also serviced kit group 4215 Use with axle 7200 7245 7300 1987 Cup driving pinion bearing rear tt MB02011 Cone and roller drive pinion rear bearing M802048 Spacer driving pinion bearing 1 5 16 1 0 x 15 32 long collapsible also serviced in kit qroup 4209 Shim pinion bearing serviced only in kiteqroup 4209 Slinger pinion shaft oil Seal assy drive pinion oi 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 1056 Spare Parts REF PART NO Ne 10 r2 242801 242816 2416006 242831 242817 122813 362805 DESCRIPTION Rubber Spring Lever Pivot Lubrication fitting Clevis pin 3 8 x 1 Yoke Master cylinder Bolt 3 8 NC x 3 QT
17. domestic environment this product may cause radio interference in which case the user may be required to take adequate measures Aug 2006 9 Delta Q Technologies Corp All rights reserved PN 710 00xx Rev 1 V1 16 45 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 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 MOTREC ILLUSTRATED ACCESSORIES Red Tail Brake light Housing Bulb 12V Back up lamp Grommet 12V 24V Clear lamp 12V Bulb 12V 3069012R 3117240001 3269001 3669012 3669012 3069012 1269008 Pedestral head lamp 12V Bulb 12V Bulb 24V Headlight Left Right Bulb H L Bulb Turn Bulb Mark 2569001 2569001B 4469001 3111480003 3111480004 3111480006 3111480008 3111480007 Headlight Left Right Bulb H L Bulb Turn Bulb Mark 3111480003 3111480004 3117480001 3117480003 3117480002 Horn button VIP 2330014 Horn button column mount 246210 Horn button dash mount 266210 3109250001 Turn signal switch 24
18. over under temp anti tiedown fault or overheated motor O O LO Lo S Note Only one fault is Indicated at a time and faults not queued up Refer to the troubleshooting chart Table 7 for suggestions about possible causes of the various faults Operational faults such as a fault in SRO sequencing are cleared by cycling the interlock switch or keyswitch 2287 74 Curtis Speed Controller PROGRAMMING PARAMETERS E 290HD 348 480 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 56 regulations and in this manual Before installing and or programming the PMC park the vehicle on a flat level surface lift the wheels off the ground and secure with jack stands of adequate capacity Don t connect charger Programmable controllers must be programmed using the parameter settings in this service manual before connecting the motor to avoid sudden vehicle movement and accident Do not try to increase motor speed by changing parameter settings in the speed controller it can cause accident and severe damage to the motor VOLTAGE NOMINAL BATTERY VOLTAGE IN VOLTS THRO DEADBAND Thr Neutral deadband of 5kohms pot THROTTLE MAX Thr Input req d for 100 5kohm pot M4 BRAKE C L 1 FIELD MAP START Armature current at wi
19. 36xx 48xx 72xx 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 delta 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 desassembler le chargeur referer toute reparations aux personnes qualifi s Pas l usage des enfants Tel 604 327 8244 Fax 604 327 8246
20. 5 C or lt 25 C Clears when heatsink Excessive load on vehicle temperature returns to Improper mounting of controller within acceptable range ANTI TIEDOWN Mode switches shorted to B Release Mode Select 1 Mode Select 1 tied down to select Mode 2 or Mode 4 permanently MOTOR HOT Field resistance motor hot setpoint When resistance setpoint MOTOR WARM Field resistance motor warm setpoint When resistance setpoint Fig 21 Curtis 840 Spyglass 3 LED 3 LED Spyglass The hourmeter LED lights when the LCD and 6 LED models is displaying hourmeter data The BDI LED lights when the LCD is displaying BDI It flashes when BDI drops to lt 10 The Fault LED flashes to indicate an active fault and the fault code appears on 8 character LCD display the LCD The word SERVICE is displayed at key on if either service timer has expired Hourmeter LED green Y Fault LED BDI LED yellow 6 LED Spyglass The three green BDI LEDs function as a bargraph showing BDI between 52 and 100 Yellow LED 36 51 BDI Fault LED red Red LED steady 20 35 BDI Red LED flashing 0 19 BDI 8 character LCD display The Fault LED flashes to indicate an active fault and the fault code appears on 0 1 ingen la 9 green The word SERVICE is displayed at key on if either service timer has expire
21. 5 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 area set for Do not operate it when charging To interrupt a charging cycle disconnect the AC plug disconnecting the DC plug or a battery terminal or 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
22. 6050 Multi LED Red Tail Brake Light 3111000006 Grommet 3111000008 Plug 3119000009 Horn button Limit switch 3030015 Multi LED Back up Light 3111000007 Strobe light 3111000013 Grommet 3111000008 Plug 3119000009 Horn 12V 246003 24V 246013 Red Tail Brake light 12V 386002 46 Spare Parts BATTERY CAPACITY Analog Voltmeter 12 24V 36 48V 3069007 2469002 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 Wiper motor 12V 24V 3113000001 486211 Wiper arm 2800000001 Wiper blade 14 Blade 18 Blade Em Pantograph wiper arm 246233A 2800000002 2800000003 Pantograph wiper blade 246233 Cab heater 12V 36V 48V 3103300001 3669008 4869020 3669006 amp 12V Dome light 12V Fan 3669013 47 Headlamp 12V 3111300001 Bulb 12V 3111300002 Red Pilot light 12V 246212 Bulb 12V 246212 gm Back up alarm or Motion beeper 12 48V 3100000001 72 80V 3105720001 12 24V Adjustable 3100000002 Spare Parts CONVERTER INSTALLATION Installation and Trouble Shooting Guide SY1200 25 The SY1200 25 is a state of the DC OC converter There are many new features and special care is required to install this unit properly If you have problems with the cpe
23. ACT POINTS TENSIONING Check the force F required to provide a deflection of 1 8 in If the measured force 15 less than 15 Ibs then lengthen centre distance C P SPAN LENGTH D DIAMETER 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 l 2 pe ID n 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 Fi
24. D OIL SEAL 42999 S B 253 3620024 3 0 O D OIL SEAL AG 4 3621001 PULLEY W80 8 O D LOCKTITE RTV 2113000004 PULLEY w90 9 0 D oY 3620011 GEAR KIT 2 3620022 4662 amp 3620022 amp 32 Spare Parts QTY PART NUMBER 373098 S100 PP 42 B E3AZ 09 2 D9AZ D9AZ D9AZ 0942 0942 D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ 0942 D9AZ E7TZ 6 2 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 5 4067 T 4067 U 4067 4067 W 4067 X 4067 Y 4067 2 4067 4067 4067 4057 0 4067 4067 AF 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 graup 4010 Gasket cover to housing use DBAZ 19562 B Shim differential bearing adjustment 241 thick 243 thick 245 thick 241 thick 249 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 271 thick 219 thick 281 thick 283 thick 285 thick 287 thick 289 thick 291 thick 299 thick
25. E ANSI B56 8 amp B56 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 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 that 1
26. FF 29 Spare Parts SPARE PARTS 30 Spare Parts REF Un AU m 12 13 14 15 16 PART NO 6106290003 280003 1005003 240501 280502 2405003 2405002 240503 240502 2301001 2500007 2500008 283001 283002 2807001 280105 280101 280107 280108 2801008 2400036 2392240003 2800011 2100021 2100027 DESCRIPTION BODY CARGO DECK BUCKET SEAT SEAT BLACK CLOTH SEAT RIGHT PIVOT LEFT PIVOT BACKREST FRAME BACKREST SEAT FRONT BUMPER FRONT PROTECTOR CABLE PROTECTOR 4 80 X 8 PNEUMATIC WHEEL 5 BOLT 4 80 X 8 FOAMFILLED WHEEL 5 BOLT 16 O D N M SOFT WHEEL 5 BOLT BAR 7T REAR FOOTSTEP 12 REAR FOOTSTEP REAR BUMPER WITH HITCH REAR BUMPER WITH PLATE SEAT SPRING KIT SEAT SWITCH KIT LIFT OUT BOX NO BATTERY PLATE FOOT SWITCH SPACER FOOT SWITCH 3 Spare Parts FORD F 150 DIFFERENTIAL 242063 BREATHER e gt c BOLT 1 2 X 3 ic 2320006 SPACER TJ 4420003 RETAINING RING GAS 2820028 4420005 RETAINER 99 2173224001 4420001 SPHERICAL BEARING 2320004 MOUNTING PLATE 6 r 3620020 CONE amp CUP 4215 4230 LOCKTITE RTV 3620020 3 Mb ne 35021185 7 AV 35 359475 S 116 CR 5098 p i mS _O 373098 5 42 8 CUT wm NN 114 E 385130 S MM 169 JE 4614 3620023 2 75 O
27. N PART RE DESCRIPTION PART F 1 PULLEY 262424 8 MOTOR BASE FORD Contact manuf 2 V BELT 242431 BELT TENSIONER 2152002 3 PULLEY 3651001 9 SEAL 484001 4 BELT EAGLE 3651002 10 BEARING 484003 5 MOTOR BASE GM Contact manuf 11 SNAP RING 484004 6 BELT TENSIONER LONG 2452005 12 NUT WASHER PACK 484006 BELT TENSIONER SHORT 2452003 15 WAVY WASHER 484013 7 PIVOT 2452002 19 HEADBAND 484015 EE HEADBAND KIT 91 107 SPECIFIC REF DESCRIPTION A89 B98 A00 SEPEX DC3 SEPEX DANA DRIVE MOTOR ASS 484000 204050 2450002 2450003 3112210001 3112230001 13 BRUSH SPRING 484010 484010 2450006 2450006 2450006 2450006 14 BRUSH PLATE 484011 484011 2450007 2450007 2450007 2450007 16 LEAD ASSY 484017 484017 N A N A N A N A 17 BRUSH 484009 484009 N A N A N A N A 18 LEAD AND BRUSH ASSY N A N A 2450008 2450008 3112210004 2450008 37 Spare Parts SEPEX MAIN CIRCUIT CIRCUIT PRINCIPAL ELECTRICAL DIAGRAM DIAGRAMME ELECTRIQUE OSA H3JOMHVHO X3d3S 2 ONIMYSO 2 1 9002 NOISUSA X3d43S 5 NIVIN XAdAS 93HION 555 SSS SN 555 55 v M 18 9HO BLK N BLK ll 38 Spare Parts ACCESSORIES DC DC CONVERTER ACCESSOIRES CONVERTISSEUR DC DC
28. 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 plugged into a battery pack the charging algorithm number will be displayed for 11 seconds see Check Change Charging Algorithm before ultimately displaying an under voltage fault fault disappears when plugged into battery pack Once a minimum battery voltage is detected the charger will enter the bulk charging constant current stage Models 912 will display the current to the battery on the bargraph and Model 912 xx1x will flash its LED GREEN off more than on to indicate 8096 charge status The length of charge time will vary by how large and how depleted the battery pack is the input voltage the higher the better and ambient temperatures the lower the better If the input AC voltage is low below 104VAC then the charging power will be reduced to avoid high input currents Models 912 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
29. Y NO REF PART NO 30 3l 32 33 34 35 36 37 34 BRAKE CONTROLS 3616013 362831 362832 362833 3616014 3616012 3616015 2416009 DESCRIPTION 8 in Handbrake lever Cable Clip Cable stop Handbrake band cable side Handbrake band Spring 20 Ibs Yoke QTY EA Spare Parts STEERING Spare Parts REF gt Q PART NO 481453 481452 481451 2530001 2530002 481454 481466 481467 2530010 2530009 481470 481471 2530007 2530005 2530006 241002 241003 281004 241005 261422 261423 401409 401423 481435 481436 2530008 481413 481414 481437 2530004 481473 DESCRIPTION COVER NUT 3 4 STEERING PROTECTOR FLANGE BLOC 3 4 BOLT 5 16 NC X 1 WASHER 5 16 LOCK WASHER 5 16 NUT 5 16 NC STEERING SHAFT PIN SCREW GEAR BOX BUSHING WASHER 3 8 LOCK WASHER 3 8 BOLT 3 8 NC X 4 1 2 PITMAN ARM LOCK WASHER NUT CASTELLADTED NUT FRONT TIE ROD LEFT AXLE RIGHT AXLE OIL SEAL TAPER BEARING HUB 5 BOLTS WHEEL BOLT WASHER CASTELLADTED NUT DUST CAP ROD END LEFT HAND ROD END RIGHT HAND NUT LEFT HAND NUT RIGHT HAND REAR TIE ROD BOLT 1 4 NC WASHER 1 4 NUT 1 4 NC PIVOT THRUST BEARING BUSHING AXLE BEAM CASTELLADTED NUT 3 4 NF 2136 Spare Parts MOTOR AND DRIVE 7774 ANN ITK 272 SESS NES 2 Z COMMON PARTS REF DESCRIPTIO
30. by the number of blinks for the first digit followed by a short pause then the number of blinks for the second digit followed by a longer pause To check change the charging algorithm a Disconnect the charger positive Fs Battery Type connector from battery pack Apply AC power and after the LED test the 3 Concorde 2xxAh AGM Algorithm will display for 11 seconds Crown CR325 dv dt b To change algorithm touch positive Deka 8GGC2 Gel connector during the 11 second display generic flooded CP dv dt period to the battery pack s positive 8 Concorde 1xxAh AGM terminal for 3 seconds and then remove Trojan J305 dV dt the Algorithm will advance after 3 DEKA 8631 Gel seconds Repeat until desired Algorithm 5 Trojan 30XHS is displayed A 30 second timeout is ww US Battery US2200 extended for every increment Troian T 105 Incrementing beyond the last Algorithm Table 1 moves back to the first Algorithm After desired Algorithm is displayed touch the charger connector to the battery positive until the output relay is heard to click 10 seconds algorithm is now in permanent memory c Remove AC power from the charger and reconnect the charger positive connector to the battery pack It is highly recommended to check a newly changed algorithm by repeating step 4 above Product warranty is two years please contact dealer of original equipment for warranty service Note This is a Class A product In a
31. cator 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 SERVICE TECHNICIANS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY Owner shall comply with ASME ANSI 56 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 bat
32. ch FIELD MAP takes effect amps M1 THRT BRK MODE 1 THROT BRAKING AS OF BRAKE C L 50 3 3 3 3 O 0 0 0 0 0 70 FIELD Field Winding Current as of Armature Current 50 M2 THRT BRK MODE 2 THROT BRAKING AS OF BRAKE 50 CURRENT RATIO CURRENT RATIO FACTOR OF 1 2 4 OR 8 STATIC RETURN TO OFF SRO TYPE M3 THRT BRK MODE 3 THROT BRAKING AS OF BRAKE 50 TAPER RATE brak Decrease rate when apporch Ospd M1 MAX SPEED MODE 1 MAX SPEED AS PWM OUTPUT 4 O 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 O O 32 O 0 M2 MAX SPEED MODE 2 MAX SPEED AS PWM OUTPUT O O MAX SPEED MODE 3 MAX SPEED AS PWM OUTPUT A 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 e eo 0 O M3 CREEP SPEED 3 CREEP SPEED AS PWM OUTPUT M4 CREEP SPEED 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 ON FF FF FF FF FF FF 50 FF FF
33. d BDI 0 100 LEDs Curtis 1243 2 Manual DIAGNOSTICS amp TROUBLESHOOTING STATUS LED DIAGNOSTICS A Status LED is built into the 1243GEN2 controller It is visible through a window in the label on top of the controller This Status LED displays fault codes when there is a problem with the controller or with the inputs to the controller During normal operation with no faults present the Status LED flashes steadily on and off If the controller detects a fault a 2 digit fault identification code is flashed continuously until the fault is corrected For example code 3 2 main contactor welded appears as OOO OO OOO OO OOO OO 342 3 2 3 2 The codes are listed in Table 8 Table8 STATUS LED FAULT CODES LED CODES EXPLANATION LED off no power or defective controller solid on controller or microprocessor fault m controller operational no faults current sensor error hardware failsafe fault M fault or motor output short static return to off SRO mM US Go NI E throttle wiper high emergency reverse circuit check fault high pedal disable HPD or expired timer throttle wiper low 2 25 2 2 Abs Q3 INS contactor driver overcurrent or field winding short main contactor welded field winding open missing contactor low battery voltage overvoltage thermal cutback due to
34. des 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 56 All 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 termi
35. e 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 1243 Generation 2 MultiMode M MOTOR CONTROLLER MODEL 2002 CURTIS INSTRUMENTS INC DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 1243cEN2 Manual p n 37044 Rev A October 2002 2531 2 INSTALLATION amp WIRING Controller for the M8 bolts maximum bolt insertion depth below the surface of the bus bar is 1 3 cm 1 2 Bolt shafts exceeding this length may damage the controller The torque applied to the bolts should not exceed 16 3 N m 12 ft lbs Two 1 4 quick connect terminals S1 and S2 are provided for the connections to the motor field winding WIRING Standard Configuration Figure 3 shows the typical wiring configuration for most applications For walkie applications the interlock switch is typically activated by the tiller and an emergency reverse switch on the tiller handle provides the emergency reverse signal For rider applications the interlock switch is typically a seat switch or a foot switch and there i
36. ear portion must not exceed the pedal case MICRO SWITCH The micro switch must deactivate the on off solenoid when the accelerator Is released turn the adjusting screw shown on figure below to adjust the micro switch height POT Remove the terminals 2 and 3 on 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 15 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 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 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 CONT
37. ikes persists replace controller 2 Current sensor out of range 3 Controller failure 1 22 HW FAILSAFE 1 1 Noisy environment Cycle KSI If problem 2 Self test or watchdog fault persists replace controller 3 Controller failure 1 3 M SHORTED 1 1 Internal external short of M to Check wiring cycle KSI 2 Incorrect motor wiring If problem persists 3 Controller failure replace controller 14 SRO 3 1 Improper sequence of KSI interlock Follow proper sequence and direction inputs adjust throttle if necessary 2 Interlock or direction switch circuit open adjust programmable 3 Sequencing delay too short parameters if necessary 4 Wrong SRO or throttle type selected 5 Misadjusted throttle pot 2 1 THROTTLE WIPER HI 1 1 Throttle input wire open shorted to When Throttle Wiper High 2 Defective throttle pot input returns to valid range 3 Wrong throttle type selected 2 2 EMR REV WIRING 1 1 Emergency reverse wire or check wire Re apply emergency reverse open or cycle interlock 2 3 HPD 3 1 Improper sequence of KSI interlock Follow proper sequence and throttle inputs adjust throttle if necessary 2 Misadjusted throttle pot adjust programmable 3 Sequencing delay too short parameters if necessary 3 Wrong HPD or throttle type selected 5 Misadjusted throttle pot SRVC TOTAL 3 1 Total maintenance timer expired Reset with programmer SRVC TRAC 3 1 Traction maintenance timer expired Reset
38. ires 10 Ibs 5 kg force to apply BELTS AND PULLEYS 10 Ibs 5kg force for 1 8 3mm deflexion X pulleys alignment see procedure WIRE TERMINALS X _ WASH BATTERY TOP WITH WATER 0 2 X 5 brushes must exceed holders ACCELERATOR ADJUSTMENT 1 8 3 mm travel to activate micro switch 0 to 50 ohms when micro switch activated 4500 to 5500 ohms with pedal down gt lt HYDR BRAKE LINES FOR LEAK STEERING ASSEMBLY as instructed BRAKE MECHANICAL LINKAGES for wear amp play BRAKE LININGS FOR WEAR 1 16 1 5 mm minimum lining thickness LUBRICATE GREASE EP 2 brake pedal pivots steering column ball joints and kingpins OIL SAE 30 LEVEL IN DIFFERENTIAL X Before adding oil check oil seals for leaks FRONT WHEEL BEARINGS PLAY X _ TIGHTEN NUTS BOLTS electric terminals drive steering brakes suspension body X REPLACE DIFFERENTIAL OIL SAE 30 LE qd 3 T CLEAN AND RE PACK FRONT HUBS L dq T dq X J SERVICE DIFFERENTIAL replace the three oil seals x 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 1s fully depressed a small backlash must remain between the gears When the plastic gear 15 released its r
39. itutes a hazard The driver is responsible for the control of the vehicle while driving and must always evaluate and care for all peculiar situations that he or she may meet while driving The driver assumes the inherent hazards related to this activity The vehicle is designed for off road use only MOTREC disclaims any liability for incidental or consequential damages to include but not be limited to personal injury or property damage arising from vehicle misuse lack of maintenance or any defect in the vehicle It is the responsibility of the Owner of the vehicle to make sure that the service technicians are properly trained as required by OSHA and ANSI B56 Service technicians shall read understand and follow instructions in the MOTREC manual before servicing the vehicle Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect the vehicle MOTREC prohibits and disclaims responsibility for any vehicle modification altering the weight distribution and stability increasing the speed or affecting the safety of the vehicle Such modifications can cause serious personal injury or property damage for which MOTREC disclaims any responsibility For Owners that are located outside North America the warranty period starts the date of shipment from the factory and the defective parts must be returned at the Owner s expense to MOTREC prior to warranty repair 21 01 2008 Table of contents TABLE OF CONTENTS
40. ms 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 not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow been dropped or otherwise damaged in any way refer all repair work to qualified Not for use by children Operating Instructions Always use a grounded outlet When using an extension cord avoid excessive voltage drops by using a grounded 3 wire 12 AWG cord 4 2 m Product Manual for QuiQ 912 24xx
41. nal 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 1f not B check wiring Turn the key switch ON check voltage between output terminal on the key switch and the terminal the battery gage if not B replace the key switch Check voltage across DC DC converter output terminals if not 12 Volt replace the converter Depress the accessory switch check voltage across accessory terminals If not 12 Volt replace the switch If 12 Volt replace the accessory FORWARD ONLY On a SEPEX motor control check the reverse signal input on the controller On a series wound motor control bad reverse contactor 15 the most probable cause of the problem Switch to reverse and check voltage on the reverse control wire If not B replace the F R switch If B turn off the key switch disconnect batteries disconnect power terminals on the F R contactors check the resistance across N C power terminals of the reverse contactor If no
42. nally 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 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 on the tie rod REMOVING amp GREASING OF FRONT HUBS required once a year Remove dust cap and cutter pin unscrew nut remove hub Inspect bearings and races for wear and replace worn bearings Replace the seal Pack the hub with wheel bearing grease and re assemble ADJUSTING FRONT HUBS Tighten spindle nut to 30 ft Ib to seat the bearing and back off the nut to the next slot Install a new cutter pin and the dust cap 15 Maintenance
43. nless steel machine screw with at least two threads of engagement and if required a paint piercing washer 3 DC Battery Connection Procedure a The green wire outputs battery voltage when the charger is not plugged into AC to provide an interlock function see Fig 1 If used a user supplied 1 fast blow external fuse must be installed inline to prevent damage Shorting or drawing more than 1A may damage charger and void the warranty b Securely fasten the black ring terminal from the charger to the negative terminal NEG NEGATIVE of the battery pack c Check that the correct charge algorithm is being used refer to section 4 Securely fasten the red ring terminal to the positive terminal POS POSITIVE of the battery pack 1A Charger Interlock Internal yc B Output O B BLKANHT Figure 1 4 Check Change Charging Algorithm The charger comes pre loaded with algorithms for batteries as detailed in Table 1 If your specific battery model is not listed please contact Delta Q Each time AC power is applied with the battery pack NOT connected the charger enters an algorithm select display mode for approximately 11 seconds During this time the current Algorithm is indicated on the 80 LED Models 912 xx0x or on the single LED Models 912 xx1x A single digit Algorithm is indicated by the number of blinks separated by a pause A two digit Algorithm is indicated
44. r 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 PMC has HPD safety feature that prevents the vehicle from moving 1f the accelerator pedal 15 depressed before the key switch 1s 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 15 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 a malfunction Check F R switch Turn on the key switch and set to forward Check voltage between the forward terminal and the
45. reticn 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 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 Ne metal surface for proper heat dissipation A 4 19 nep vertical mounting position is best to maximize the convection process The unit will shut down 5 0 gt thermally under high currents if not properly S SS BLACK 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 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 the 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
46. rkings 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 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 Q 10 Maintenance
47. s no emergency reverse MODE MODE EMERGENCY SELECT SELECT 1 2 REVERSE FORWARD REVERSE INTERLOCK 5 POT THROTTLE TYPICAL ELECTRO MAGNETIC BRAKE MAIN D KEY CONTACTOR SWITCH COIL POLARITY PROTECTION DIODE CONTROL MAIN PUSE CONTACTOR B POWER FUSE altaf reverse wiring check optional Fig 3 Srandard wiring configuration Curtis 1243GEN2 controller Curtis 1243cEN2 Manual 7 DIAGNOSTICS amp TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING The 1243GEN2 controller provides diagnostics information to assist technicians in troubleshooting drive system problems The diagnostics information can be obtained by observing the appropriate display on the handheld programmer the fault message displayed on the Spyglass gauge the fault codes issued by the Status LED or the fault display driven by the controllers fault outputs Fault 1 and Fault 2 Refer to the troubleshooting chart Table 7 for suggestions covering a wide range of possible faults PROGRAMMER DIAGNOSTICS The handheld programmer presents complete diagnostic information in plain language Faults are displayed in the System Faults Menu and the status of the controller inputs outputs is displayed in the Monitor Menu Accessing the programmers Fault History Menu provides a list of the faults that have occurred since the fault history file was last cleared Checking and clearing the fa
48. stor 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 15 sealed the static strap makes good contact with the ground the motor 15 sealed by bands the cable protectors are properly installed Keep cables and wires clear from mechanical and rubbing action Make sure that cable insulation is free from cutting or visible damage Make sure that EE Rated cable protectors are properly installed Before replacing a fuse or circuit breaker identify the cause of failure and repair Programmable controllers must be programmed using the parameter settings in this service manual before connecting the motor to avoid sudden vehicle movement and accident Maintenance Do not try to Increase motor speed by changing parameter settings In the speed controller it can cause accident and severe damage to the motor SEPEX speed 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 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 ma
49. t 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 motor control check the forward signal Input on the controller On a serles wound motor control a bad forward contactor 1s 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 potentiomete
50. teries 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 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 resi
51. terrupting 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 accepted limits 6 FLASH QuiQ Fault an internal fault has been detected If Fault 6 is again displayed after interrupting AC power for at least 15 seconds the charger must be brought to a qualified service depot Maintenance Instructions 1 2 3 For flooded lead acid batteries regularly check water levels of each battery cell after charging and add distilled water as required
52. 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 are 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 poorly but at 25 amps 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 48 Spare Parts BATTERY DISCHARGE INDICATOR HOBBS This indicator monitors
53. to level specified by battery manufacturer Follow the maintenance and safety instructions recommended by the battery manufacturer Make sure charger connections to battery terminals are tight and clean Do not expose charger to oil dirt mud or to direct heavy water spraying when cleaning vehicle See flip side for Product Specifications and Installation Instructions for qualified personnel 44 Spare Parts Specifications Voltage nom V __ Voltage mnax V _ Currentmax A Mechanical models Dimensions 28 0 x 24 5 x 11 0 cm 11x 9 7 x 4 3 Battery Type Reverse Polarity Short Circuit Electronic protection auto reset Electronic current limit AC Inp Voltage max Vrms Frequency Hz Current max Arms Current nominal Arms Power Factor 12A 104VAC reduced 20 lt 104 20 98 at nominal input current All models i a 10AQ 120 5 230VAC Weight 0 5 kg lt 11 Ibs w standard output cord Environmental Enclosure IP46 Operating 30 C to 50 C 22 F to 122 F derated Temperature 2212 22 30 below 0 C Storage Temperature 40 to 70 C 40 F to 158 F input connector DC output connector IEC320 C14 require 21 8m localized cord OEM specific w 12AWG wire
54. ult history file is recommended each time the vehicle is brought in for maintenance For information on 1311 programmer operation see Appendix B If you are using the older 1307 programmer refer to existing documentation SPYGLASS DIAGNOSTICS The eight character LCD on the Spyglass displays a continuous sequence of hourmeter battery state of charge and fault messages Fault messages are displayed using the same codes that are flashed by the LED see Table 8 For example the LED flashes 3 2 for a welded main contactor OOO OO OOO OO OOO OO 2 2 CRA 332 and the corresponding Spyglass message is CODE 32 When a fault message is being displayed the red Fault LED labeled with a wrench symbol flashes to catch the operators attention The LCD also displays a warning when either service timer expires The service warning is not considered a fault and the red Fault LED does not flash The word SERVICE is displayed for about 20 seconds on each key on after the hourmeter 15 displayed The Spyglass is available in 3 LED 6 LED models see Figure 21 25 DIAGNOSTICS amp TROUBLESHOOTING Table7 TROUBLESHOOTING CHART LED PROGRAMMER FAULT CODE LCD DISPLAY CATEGORY POSSIBLE CAUSE FAULT CLEARANCE 01 NO KNOWN FAULTS 0 n a n a 1 1 CURRENT SHUNT FAULT 1 1 Abnormal vehicle operation causing Cycle KSI If problem high current sp
55. 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 56 Do not drive this vehicle unless you are a certified operator as required by OSHA 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 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 indi
56. ve a charger connected for more than 20 hours FREQUENCY OF CHARGE When battery is discharged to its 20 state of charge it is best to charge immediately Batteries require a low current equalization charge min 4 hours at least every week to equalize battery cells improve battery performance and life in number of cycles Never leave a charger connected for more than 20 hours STORAGE Keep the battery from getting cold it would loose its capacity 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 1s shorted voltage drop may occur only when there 1s current 17 Maintenance CHARGER WARNING Always unplug the AC and DC electrical cords before attempting any repairs to the charger CHARGER DOES NOT TURN ON Dc 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 dio
57. with programmer TOTAL DISABLED 3 1 Total disable timer expired Reset with programmer TRAC DISABLED 3 1 Traction disable timer expired Reset with programmer 2 4 THROTTLE WIPER LO 1 1 Throttle pot wire open or shorted to B When Throttle Wiper Low 2 Wrong throttle type selected input returns to valid range 3 Defective throttle pot 3 1 FIELD SHORT 1 1 Main contactor coil shorted Check contactor coil and 2 Field winding shorted to B or B field winding cycle KSI 3 Field resistance too low 32 MAIN CONT WELDED 1 1 Main contactor stuck closed Check wiring and contactor 2 Main contactor driver shorted cycle KSI 3 3 FIELD OPEN 1 1 Field winding connection open Check wiring and cycle KSI 2 Field winding open 34 MISSING CONTACTOR 1 Main contactor coil open Check wiring and cycle KSI 2 Main contactor missing 3 Wire to main contactor open Curtis 1243 2 Manual 256 72 DIAGNOSTICS amp TROUBLESHOOTING Table7 TROUBLESHOOTING CHART cont d PROGRAMMER FAULT LCD DISPLAY ATEM POSSIBLE CAUSE FAULT CLEARANCE LOW BATTERY VOLTAGE 2 Battery voltage undervoltage cutback When voltage rises above Corroded battery terminal undervoltage cutoff point Loose battery or controller terminal OVERVOLTAGE Battery voltage gt overvoltage shutdown When voltage falls below limit overvoltage cutoff point Vehicle operating with charger attached THERMAL CUTBACK Temperature gt 8
58. y No compensation will be allowed for delays To initiate warranty coverage on any MOTREC vehicle the Dealer must complete and return the Sales Installation Report to MOTREC within 30 days after delivery to the Original Retail Purchaser or within 90 days after the delivery date to the Dealer which ever occurs first Failure to follow these procedures will result in considering the warranty coverage effective as of the shipment date from the factory The defective vehicle must be returned at the Owner s expense to an authorised MOTREC Dealer within 30 days after failure The Owner will not be charged for parts and labour required for warranty repairs which must be performed by an authorised MOTREC Dealer only The vehicle will be returned at the owner s expense The Warranty Claim Forms must be completed and returned with the defective part s to MOTREC within 30 days after repair was done No compensation will be allowed for damages caused by vehicle downtime It is the responsibility of the owner of the vehicle to make sure that the driver is properly trained and instructed in the safety features and operation of the vehicle including vehicle stability as required by OSHA and ANSI B56 Operators shall read understand and follow the safety and operating instructions in MOTREC Manual before driving the vehicle Operators shall not be permitted to drive the vehicle unless a complete and adequate training has been provided Driving a vehicle const

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