T-248 OK - 313 Velocity
Contents
1. 6002 1 _ POTENTIOMETER 363 M PLASTICGEAR 605 SPRING 1246208 1 _ SEATSWITCH SEAT MOUNTED 366216 1 _ __ F R SELECTOR TILT TEL COLUMN 366212 __ FIR SELECTOR ROCKER TYPE _ 266211 58 LIGHT SWITCH ROCKER TYPE HORN BUTTON COLUMN MOUNT 1 3669004 A2 Bl B2 B3 El E2 B F3 F5 Gl 1 HORN BUTTON FLOOR MOUNT 12 3669004 S15 S16 HOUR METER CONNECTOR SPEED CONTROL CONNECTOR STATICSTRAP 5011 11 Consult Motrec illustrated parts Ul 1 X2 41 Spare Parts Strobelight polemount Amber 12 80V 3116000001 Red 12 80V 2469001 Blue 12 80V 3690008 Strobelight cab mount Amber 12 48V 3116250001 Red 12 48 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 12V 2469021 24V 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 3669012A 3069012 1269008 Pedestral head lamp 12V Bulb 12V Bulb 24V Headlight Left Right Bulb H L Bulb Turn B2. LU 1 248 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1016387 amp UP Printed in Canada One Year Limited Warranty Effective April 25 2005 Inc MOTREC hereby warrants to the Original Retail Purchaser Owner that any of its vehicles shall be free from any defect in materials for a period of 90 DAYS while in the possession of such Original Retail Purchaser This warranty IS NOT TRANSFERABLE to any subsequent Buyer The warranty period is extended to one year or one thousand 1 000 hours which ever first occurs on the electric motor differential parts that bathe in oil and the electronic speed controller MOTREC makes no warranty or representation with respect to the internal combustion engine tires and batteries since their respective manufacturers cover such parts Accessories light gage horn etc electrical contacts switch solenoid contactor relay diodes amp fuses belts amp pulleys filters amp spark plugs lubricants brake linings amp shoes brake drums amp discs seals seats trim and other items subject to wear are not included in this warranty nor is any item that in MOTREC sole opinion shows evidence of neglect misuse abuse collision or alteration This warranty shall not apply to normal maintenance requirements as described in the User Manual and to damages during shipment The latter is the carrier s responsibility No compensation will b
3. 23 re 33 d 24 _ a gt lt Ut 1 1 Be 23 22 REF PART NO 19 2230014 RB 20 2230014 MBK 21 2235001 22 2235003 23 2235004 24 2235002 25 26 241006 27 29 231404 30 231405 33 1022002 34 2230022 35 366212 36 800TXA 37 2361001 38 366221 39 201434 37 DESCRIPTION RIGHT BRACKET HORN BRUSH KIT SHAFT OIL SEAT TAPER BEARING HUB BOLT 1 2 NF BUSHING NUT 1 UNIVERSAL JOINT PIVOT CHAIN STOPPER SWITCH CONTACT BLOC NAMEPLATE F R GREY HANDLE WASHER Spare Parts MOTOR AND DRIVE SSS 22 ISS 27777227244 N V 2 COMMON PARTS REF DESCRIPTION PART REF DESCRIPTION PART 1 PULLEY 262424 8 MOTOR BASE FORD Contact manuf 2 V BELT 242431 BELT TENSIONER 2152002 3 PULLEY 3651001 9 SEAL 484001 4 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
4. 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 5 1200 25 SY1200 25 is a state of the an DC OC converter There are many new features and special care is required to install this unit properly If you have problems with the operation 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 i The black wires common however due to the high currents developed in this unit it is necessary to maintain proper electron flow to reduce noise The converter must be mounted on a Ne metal surface for proper heat dissipation A 4 19 N RED vertical mounting position is best to maximize the R convection process The unit will shut down 5 0 thermally under high currents if not properly 5 55 gt 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 fac
5. 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 15 erratic sudden stop after a bump or shock erratic starts requiring several pedal cycles A bad F R contactor 1 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 if the accelerator pedal 15 depressed before the key switch is ON and seat switch is activated may also 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 PMC is also equipped with an internal thermal protection that cutback the current until the PMC has cooled down 19 Maintenance NO MOTION Make sure that the PMC surface is clean and dry check the terminal areas Dust Particles or acid contamination can create
6. 4 1 6 ASI TETTI 9 Wu ci gt 2 w 15 Maintenance BATTERY MAINTENANCE WARNING It is the responsibility of the owner of this vehicle to ensure that the service technicians are properly trained read and obey the safety rules and guidelines in this manual ANSI B56 Maintenance operations must be made by properly trained service technicians only Before any maintenance work park the vehicle on a flat level surface turn off all the switches set to neutral remove the key lift the wheels off the ground and secure with jack stands of adequate capacity Keep charger disconnected while doing any maintenance work Always wear a face shield and scarf when working around 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 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 thoro
7. 481434 481442 481440 481441 3614002 3614003 DESCRIPTION DISC HYDRAULIC BRAKE REAR AXLE LOCK WHEEL STUD LEFT CALIPER RIGHT CALIPER REPAIRE KIT CALIPER OIL SEAL NEEDLE BEARING NUT FLAT WASHER PULLEY W90 MOUNTING PLATE CALIPER OIL SEAL TAPERED BEARING HOUSING SPACER BREATHER SPACER TAPERED BEARING SHIM GEAR KIT SHIM TAPERED BEARING CASE WASHER GEAR KIT WASHER GEAR KIT SCREW SHAFT CAP BOLT DRAIN PLUG DIFFERENTIAL COVER BOLT BRAKE HOSE FOR DISC BRAKE BRAKE PADS BOLT LONG BOLT SHORT HYDRAULIC BOLT WASHER BUSHING LONG BUSHING SHORT 34 Spare Parts REF PART NO 242800 242816 2316008 202811 242817 122813 362805 2216007 2216021 2216019 2216018 2530001 BRAKE CONTROLS DEADMAN SEAT BRAKE DESCRIPTION RUBBER PEDAL SPRING LEVER PIVOT LUBRICATION FITTING CLEVIS PIN 3 8 X 1 YOKE MASTER CYLINDER BOLT 3 8 NC X 3 ROD 15 ROD 17 SEAT BRAKE PLATE SEAT BRAKE PLATE FLANGE BLOC REF 19 25 26 27 28 29 31 33 34 35 36 43 44 45 35 367002 2216017 2216009 2316012 2316013 2290002 362831 362833 2316005 3616014 3616015 2216011 262816 DESCRIPTION MICRO SWITCH BRASS BUSHING CABLE PULL BRACKET TUBE HOLDER ADJUSTMENT ROD ROD END 1 2 CABLE CABLE STOP HANDBRAKE PAD HANDBRAKE PAD SPRING 20 Ibs CABLE ADJUSTMENT SPRING HAFT NUT 9 16 NF Spare Parts STEERING WHEEL AND FRON
8. Be sure the driver uses brakes when you slow or stop the towing vehicle Do not exceed 5 MPH or carry any passenger while towing this vehicle Instructions OPERATING INSTRUCTIONS It is the responsibility of the owner of this vehicle to ensure that the operator understands the operating characteristics of this vehicle and obeys the safety instructions in this manual and ANSI ITSDF B56 8 amp 9 Standards Do not drive this vehicle unless you are a certified operator as required by OSHA BEFORE TURNING ON KEYSWITCH Set to neutral set parking brake check for visible damage check brake pedal AFTER TURNING ON KEYSWITCH Check safety devices seat switch reverse alarm motion beeper strobe light and all other safety devices BATTERIES Never open the battery compartment unless you have received proper training for battery maintenance Batteries emit explosive hydrogen gas that can be ignited by a spark or loose terminal Battery acid causes severe damage to eyes or skin Flush the contaminated area immediately with water Park the vehicle in a well ventilated area for battery charging Most battery chargers come with an electronic control that starts when the charger is plugged and stop when the battery is fully charged To interrupt the charging cycle disconnect the AC 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
9. Table 5 for suggestions about possible causes of the various faults Curtis PMC 1244 Manual 27 79 Curtis Speed Controller PROGRAMMING PARAMETERS E 290HD E 348 480 E 500 E 660 T 248 448 WARNING The owner of this vehicle shall ensure that the service technicians are gualified properly trained and obey the safety rules and guidelines in OSHA and ANSI B56 regulations and in this manual Before installing and or programming the PMC park the vehicle on a flat level surface lift the wheels off the ground and secure with jack stands of adequate capacity Don t connect charger Programmable controllers must be programmed using the parameter settings in this service manual before connecting the motor to avoid sudden vehicle movement and accident Do not try to increase motor speed by changing parameter settings in the speed controller it can cause accident and severe damage to the motor VOLTAGE NOMINAL BATTERY VOLTAGE IN VOLTS THRO DEADBAND Thr Neutral deadband of 5kohms pot THROTTLE MAX Thr Input req d for 100 PWM 5kohm pot M4 BRAKE C L 1 FIELD MAP START Armature current at wich FIELD MAP takes effect amps 1 MODE 1 THROT BRAKING AS OF BRAKE C L 50 3 3 3 3 o O 0 0 0 0 0 70 O FIELD MAP Field Winding Current as of Armature Current 50 M2 THRT BRK MODE 2 THROT BRAKING AS OF BRAKE C L 50 CURRENT RATIO CURRENT RATIO FACTOR
10. OF 1 2 40R8 STATIC RETURN TO OFF SRO TYPE M3 THRT BRK MODE 3 THROT BRAKING AS OF BRAKE C L 50 TAPER RATE Li brak Decrease rate when apporch Ospd M1 MAX SPEED MODE 1 MAX SPEED AS PWM OUTPUT 4 2 O 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 M3 MAX SPEED MODE 3 MAX SPEED AS PWM OUTPUT gt gt O O O M4 MAX SPEED MODE 4 MAX SPEED AS PWM OUTPUT 1 CREEP SPEED MODE 1 CREEP SPEED AS PWM OUTPUT M2 CREEP SPEED MODE 2 CREEP SPEED AS PWM OUTPUT O O 0 0 M3 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 ON FF FF FF FF FF FF 50 FF FF FF 28 Spare Parts SPARE PARTS 29 Spare Parts BODY REF PART NO DESCRIPTION 1 2300044 REAR COVER 2 2205001 GS 12 GRAMMER SEAT 2205002 GS 12 GRAMMER SEAT SWITCH 2305002 DELUXE GRAMMER SEAT 2200022 SEAT SPACER 2200024 SEAT SPACER WHIT STOPPER 3 2807001 5 BOLT SOLID BLACK RUBBER WHEEL 2207004 5
11. carry cargo that is longer wider or higher than this vehicle e Always depress slowly the accelerator for smooth acceleration Avoid stunt driving or horseplay e Avoid sharp turns always slow down before turning to prevent vehicle overturn or trailer jack knife Vehicle 1 more sensitive to overturn and jack knife when traveling on inclines or when carrying a heavy load e Always drive straight up and down the face of an incline never across the face to prevent overturn and trailer jack knife Drive slower and start applying brakes sooner on inclines to adjust for longer stopping distance e Use extra care and drive slowly in reverse in congested areas or on wet or slippery ground e Keep to the right under normal conditions Maintain a safe distance from all objects e Slow down and sound the horn when approaching a corner or other blind intersections e Before leaving the vehicle park on 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
12. current leaks and cause a PMC malfunction Check F R switch Turn on the key switch and set to forward Check voltage between the forward terminal and the terminal on the battery gage check voltage between the reverse terminal and the terminal on the battery gage if both B replace the F R switch Check switches and wiring Disconnect control terminals on the PMC and check all control signals Ii 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
13. differential pinion must turn freely when the parking brake is released On pinion brake use spacers at pad fixed ends to reduce space between pads and pulley to Imm To install new cables and stoppers insert the new cable through the hand lever end pull the cable out from the brake assembly end insert the stopper on the cable and leave a maximum play of 1mm for a two cable system make sure that cable length is the same at hand lever end tighten 4 ncx3 4 grade 5 bolt in stopper at 8 LbFt 1 INM torque cable must extend 1 5 4cm out of the cable stopper cut cable excess Once cable play has been checked and or adjusted turn the knob on the brake lever until a force of 75 Lbs or 34 kg is required on the handle to set the parking brake BRAKE PEDAL If the brake pedal becomes soft or spongy air may have entered the hydraulic system and the brake system has to be bled 1 fill the master cylinder with brake fluid DOT 3 bleed front callipers one at a time by having someone applying a steady pressure on the brake pedal and close the bleeder before allowing the brake pedal to return to up position fill the master cylinder with brake fluid DOT 3 bleed rear wheel brakes one at a time following the same procedure fill the master cylinder with brake fluid DOT 3 clean every fitting and line remove traces of oil apply a continuous pressure on the brake pedal for about five minutes Finally inspect brake lin
14. 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 H 88048 QTY AR AR AR AR AR 235 PART NUMBER FORD WEC NON LOCKING REAR AXLE SERVICE PARTS LIST NO 237 DSAZ D9AZ D9AZ D9AZ DIAZ 2 E7TZ E7TZ DSAZ 0942 ETTZ E7TZ C7AZ C7AZ B7A D5AZ ESDZ E7UZ 4067 4067 AG 4067 4067 AJ 4067 4067 AL 4200 4204 4204 4211 4215 4216 4221 4222 4228 4228 4230 4230 4628 4630 A 4662 A 4663 4670 4676 4851 4851 389546 5100 170 6612 4859 4859 DESCRIPTION Shim differentia bearing adjustment Cont d 299 thick 301 thick 803 thick 805 thick 4307 thick Differential assy refer to group in Section 40 Case assy differential Use with axle 7200 724S 730D 1987 Shaft differential pinion kit use with axle 7200 7245 7300 1987 Consists of 1 E7TW 4211 Shaft 1 0882 4241 Pin Pinion kit use with axle 720C 7248 7300 1987 Consists of 2 4215 AA Pinion 2 7 2 4230 Washer Bolt differential case self locking 7116 20 x 3 4 Cone and roller
15. 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 XP REVERSE ALARM DEADMAN SWITCH X STATIC STRAP min 2 contact with ground _ X j TIRE PRESSURE pressure rating on tire _ j x gn j jh CHECK FILL BATTERIES add distilled water to cover plates Fill to recommended level after batteries have been fully charged i ____ fi EE Rated CABLE PROTECTORS SEALED MOTOR MASTER CYLINDER FLUID DOT 3 X j BRAKE PEDAL TRAVEL STEERING FOR PLAY X j PARKING BRAKE LEVER X requires 75 lbs 34 kg force to apply BELTS AND PULLEYS 10 lbs 5kg force for 1 8 3mm deflexion X CLEAN TIGHTEN WIRE TERMINALS EX WASH BATTERY TOP WITH WATER x j stiva i O j x j 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 HYDR BRAKE LINES FOR LEAK a BRAKE MECHANICAL LINKAGES x for wear amp play BRAKE LININGS FOR WEAR 1 16 2 mm minimum lining thickness 6 mm minimum thickness for brake pulley lining LUBRICATE GREASE EP 2 brake pedal pivots steering column ball Joints and kinepins Before adding oil check oil seals for leaks FRONT WHEEL BEARIN
16. AD 15 GROUNDED AUXILIARY SWITCH IS SHOWN WITH THE TREADLE IN THE UP POSITION SWITCH WILL ACTUATE AT BEGINNING OF TREADLE STROKE SYMBOLS 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 CONTACT POINTS TENSIONING Check the force F required to provide a deflection of 1 8 in If the measured force is less than 15 Ibs then lengthen centre distance C P SPAN LENGTH D DIAMETER IN d DIAMETER IN R PONGE que q DEFLECTION IM C CENTER DISTANCE IN 13 Maintenance HYDRAULIC amp PARKING BRAKES Revision 2008 02 06 DRUM BRAKES Remove brake drums and check lining wear Replace shoes and springs if the lining thickness is 1 16 2mm or less Turn the brake adjustment to reduce the clearance between lining and drum Wheels must turn free when the pedal is released DISC BRAKES Check pad linings Replace pads if lining thickness is 1 16 2 mm or less PARKING BRAKE Replace cables and stoppers if cable play exceeds 1 8 4mm Wheels and or
17. BOLT 16 O D MOLD ON WHEEL 2807010 5 BOLT EXTRA DEEP 4 00 8 WHEEL 4 2200018 ROLLER 2200019 SHAFT 2200010 BEARING 5 2205003 LATCH 6 2301001 BUMPER 7 2500250002 DASH PLATE 30 Spare Parts FORD F 150 DIFFERENTIAL 4014002 lt _ 481434 481430 F gt 481440 481431 L E 481441 481442 36 14003 x 242063 BREATHER 2320004 MOUNTING PLATE _ BOLT 1 2 X 3 2320006 SPACER 4420003 RETAINING RING 4420005 RETAINER 242054 BOLT 4435006 481433 emeret E 52 dh o 4420001 SPHERICAL BEARING 4420002 SEAL pee 3204 _ __ _ MN AJA per 3230 4236 AN 3620020 A OW PO T yia E EJ RR 4215 LOCKTITE RTW 3520020 _ 373088 8 CONE amp CUP 42 8 11 i i 412 4142 MAU 3584755 NN 116 aE pue Wi 3620021 2051 aos 2 Jm Vee NN 14 5 __ 373820 5 XX A d 395130 5 WM 169 JEJ 7 4 dem ana 7 3620023 275 OD OIL SEAL al KG E x messa 3620024 3 0 O D OIL SEAL 3621005 PULLEY M80 amp O D RTW 3621006 PULLEY woo 84 O D 2 9670 9 3620011 GEAR KIT 190 3620022 CONE amp CUP 29 3620022 CONE amp CUP i 3 Spare Parts QTY PART NUMBER 373098 S100
18. BRUSH ASSY N A N A 2450008 2450008 3112210004 2450008 38 SEPEX MAIN CIRCUIT CIRCUIT PRINCIPAL SEPEX ELECTRICAL DIAGRAM DIAGRAMME ELECTRIQUE Spare Parts OSA HJOHVHO Frei X3d3S ONIMVHQ 91 20 8002 31VG NOISUJA X3d3S LIN9819 NIVIN XAdAS 93HION SAR SN A LE GO GiGi CIGI ajo FE Y 19 i T E ev LE z gt 4 1997 034 MIS LHA 91S anis Wapa a 64 T i LA HAN HO HO Ho OU 9S e9 AE 10 S 39 Spare Parts DC DC CONVERTER ACCESSORIES ACCESSOIRES CONVERTISSEUR DC DC QSAJOVISVILEIHE 90 00 OOV d3AOHddV NONOVO f HOHLNV L L v0 9002 diva LO NOISUZA YALYAANOD HO VISVILVIHI LOAraNns DAULOW RED BLK c LL gt OLIN y ca La gt M 18 03 N49 La 2 x m z tc NND Y 18 Y m gt 49 NE LS N 4 v gt ES TIA 40 Spare Parts PARTS LIST F E QTY 244 5451 1 FLAB FUSE ISA 246I08K 3107000002 3669027 2 SEPEX MOTOR 41 _____
19. GSPLAY TIGHTEN NUTS BOLTS electric terminals drive steering brakes suspension body X REPLACE DIFFERENTIAL OIL SAE 30 X lii cit O CLEAN AND RE PACK FRONT HUBS SERVICE DIFFERENTIAL replace the three oil seals wheel bearings oil SAE 30 11 Maintenance ACCELERATOR GEAR Remove the cover Backlash between gears must be reduced to a minimum by sliding holder use locktite 262 to lock the three screws When the plastic gear is fully depressed a small backlash must remain between the gears When the plastic gear is released its rear portion must not exceed the pedal case MICRO SWITCH The micro switch must deactivate the on off solenoid when the accelerator 15 released turn the adjusting screw shown on figure below to adjust the micro switch height POT Remove the terminals 2 and 3 on 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 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 is on and then connect terminals 2 and 3 POTENTIOMETER BRACKET AUXILIARY SWITCH IS WIRED N O WITH BLUE LEAD TO COM amp ORANGE LEAD TON O CIRCUIT THE GREEN LE
20. PP 42 B E3AZ DIAZ DIAZ D9AZ 09 2 0942 0942 D9AZ DIAZ DIAZ DIAZ D9AZ D9AZ D9AZ D9AZ D9AZ DIAZ DIAZ DIAZ DIAZ DIAZ DIAZ DIAZ DIAZ DIAZ DIAZ DSAZ DIAZ 0942 D9AZ E7TZ 6 2 ESTZ 4033 4036 4067 4067 4067 B 4067 C 4067 D 4067 4067 F 4067 G 4067 H 4067 J 4067 4067 L 4067 4067 N 4067 4067 R 4067 5 4067 T 4067 U 4067 4067 W 4067 4067 Y 4067 Z 4057 4067 4067 4067 AD 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 248 thick 251 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 271 thick 219 thick 281 thick 283 thick 285 thick 287 thick 289 thick 291 thick 293 thick 205 thick 207 thick Gear kit differential sida usa with axla 7200 7245 7300 1987 Consists of 2 E7TZ 4228 Washer 9 E7TW 4236 Gear U washer axle shaft retaining Pin differential pinion shaft lock O ring axle shaft Bolt housing cover self locking 5 16 18 x 5 8 also serviced
21. SAFETY WARNINGS FOR OPERATORS OPERATING INSTRUCTIONS MAINTENANCE SAFETY WARNINGS FOR SERVICE TECHNICIANS DECALS AND LABELS PERIODIC MAINTENANCE CHECKLIST ACCELERATOR BELT INSTALLATION AND TENSIONING HYDRAULIC amp PARKING BRAKES DEADMAN SEAT BRAKE BATTERY MAINTENANCE 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 248 448 SPARE PARTS BODY FORD F 150 DIFFERENTIAL DIFFERENTIAL BRAKE CONTROLS DEADMAN SEAT BRAKE STEERING WHEEL AND FRONT AXLE TILT TEL STEERING WHEEL AND FRONT AXLE MOTOR AND DRIVE ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT ACCESSORIES DC DC CONVERTER PARTS LIST MOTREC ILLUSTRATED ACCESSORIES CONVERTER INSTALLATION BATTERY DISCHARGE INDICATOR HOBBS ADDENDUM CURTIS FOOT PEDAL a O 7 k 10 12 13 14 15 16 18 21 24 25 26 27 28 29 30 31 33 35 36 37 38 39 40 41 42 44 45 46 47 Instructions INSTRUCTIONS Instructions SAFETY WARNINGS FOR OPERATORS e FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAY RESULT IN SEVERE INJURY e Itis 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
22. T AXLE 11 gt M V 2 12 N 13 T 28 14 12 eb 6 g lt gt 29 duh e m s P 5 CL LEA Z 24 33 gt IL SE gt E gt SP JO a C 25 8 ALL f 7 NI 23 A 22 SA 26 ar 27 REF PART NO DESCRIPTION REF PARTNO DESCRIPTION 1 481451 STEERING WHEEL 14 201434 WASHER 2 3 8 3 4 21 2235001 SHAFT 3 LOCKW ASHER 3 8 22 2235003 OIL SEAT 4 481454 PIN 23 2235004 TAPER BEARING 5 231401 FORK 24 2235002 HUB 6 201423 BALL BEARING 25 241005 WHEEL NUT 7 BOLT 1 2 1 1 2 26 241006 BUSHING 8 LOCKWASHER 1 2 27 NUT 1 9 481453 COVER 28 231403 TUBE 10 481452 NUT 3 4 NF 29 231404 UNIVERSAL JOINT 11 231402 SHAFT 30 231405 PIVOT 12 3030020 BUSHING 33 1022002 CHAIN 13 3030021 OIL SEAL 236 lt Spare Parts REF PART NO 1 2330013 2 3 4 481454 5 231401 6 201423 7 8 9 2330014 10 2230014 11 2230020 12 2230018 13 2230019 14 2330015 15 2230015 16 2230016 17 2230017 18 2230023 TILT TEL STEERING WHEEL AND FRONT AXLE 2 1 DESCRIPTION STEERING WHEEL BOLT 3 8 NC X 3 4 LOCKW ASHER 3 8 PIN FORK BALL BEARING BOLT 1 2 X 1 1 2 LOCKW ASHER 1 2 HORN BUTTON TILT TEL COLUMN SHAFT NYLON COUPLER SHAFT UNIVERSAL JOINT SUPPORT TILT TEL COLUMN NYLON WASHER NYLON BUSHING CASE F R 4 d n ja 29 AH 2 S ne 1 22 30 lt A ii
23. TY WARNINGS FOR SERVICE TECHNICIANS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY Owner shall comply with OSHA and ANSI ITSDF B56 8 amp B56 9 Standards for vehicle maintenance Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect carriers vehicles tractors and batteries Before any maintenance work park the vehicle on flat level surface turn off all switches remove key lift wheels off the ground and secure with jack stands of adequate capacity Don t connect charger Keep clear from moving parts such as tires sheaves and motor Follow the maintenance instructions applicable to the type of repair maintenance or service Always wear a face shield and gloves when working around batteries Before opening the battery compartment disconnect the charger turn off all switches and remove the key Batteries emit highly explosive gases which greatly increase when charging do not disturb connections or produce sparks around batteries to avoid a battery explosion and acid splashing Battery acid causes severe damage to eyes or skin Flush contaminated area immediately with water Use insulated tools to avoid sparks that can cause battery explosion and acid splashing Use two counteracting tools double wrench technique when disconnecting or tightening terminals on the battery and the speed controller to avoid cracking the terminal or battery post welds Before clean
24. ations 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 POLARITY PROTECTION DIODE CONTROL FUSE B Fig 3 Standard wiring configuration Curtis PMC 1244 controller Curtis PMC 1244 Manual 24 8 8 DIAGNOSTICS amp TROUBLESHOOTING Curtis PMC 1244 Manual 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 complete diagnostic information in plain language Faul
25. comply with OSHA and ANSI ITSDF 856 8 amp 856 9 Standards for vehicle use safety rules operator training and certification Do not drive this vehicle unless you are a qualified operator e not drive this vehicle under the influence of drugs or alcohol e Do 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 Do not open motor compartment Keep clear from moving rotating wheels sheaves etc or lifting parts e Never carry more passengers than number allowed for this vehicle Wait until all occupants are seated and holding on before moving Always keep all body parts inside vehicle Keep both hands on steering wheel e Do not exceed the vehicle cargo load capacity and gross trailing weight capacity rated for flat hard even surface Different operating conditions such as loose terrain or ramps reduce vehicle 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
26. differential bearing LM803049 Cup differential bearing LM603012 Washer differential side gear thrust also serviced in kit group 4236 Use with axle 7200 724S 7300 1987 Washer differential pinion thrust also serviced in kit group 4215 Use with axle 47206 7245 7300 1987 Cup 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 qroup 4209 Shim pinion bearing serviced only in Kit group 4209 Slinger pinion shaft oil Seal assy drive pinion oil ESDW 4676 Flange assy universal joint axlo end 1330 size 1987 Locknut and washer assy flange to pinion 3 4 20 also serviced in kit group 4209 Deflector driving pinion oil sea Plastic From 1 86 1986 Spare Parts DIFFERENTIAL gt 28 29 s 24 28 33 Spare Parts REF D 12 13 14 15 16 17 18 19 20 21 22 23 24 27 28 29 30 31 32 33 34 35 36 37 38 39 42 43 44 45 46 47 48 481433 2173236001 242053 242054 481430 481431K 481430RK 2420011 2420010 242058 242059 2113000002 2122236001 242060 242061 2235008 2320006 242063 242064 242065 242066 242067 242069 242070 242071 242072 242073 242074 3620027 242076 3620006 242078 242079 242080 2420019 481432 2814003
27. e allowed for delays To initiate warranty coverage 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 Th
28. e 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 18 02 2008 Table of contents TABLE OF CONTENTS INSTRUCTIONS
29. er 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 1s found and part of the text can t be read Check decals and labels see DECAL AND LABELS page Maintenance DECALS AND LABELS CAUTION The images included in this section depict the decals markings installed on the vehicle It 1s of the utmost importance that theses decals markings remain unaltered and readable Else the sticker or the part baring the marking has to be replaced Dashboard security warning label General security warning label 5100000002 5100000001 Operation of this vehicle is restricted to authorized persons only Read operator s instructions in owner s manual prior to driving Operation of this vehicle is restricted to authorized persons only Read operator s instructions in owner s manual prior to driving Do not operate on roads public streets and unauthorized areas Never open battery compartment Never open motor compartment When an emergency push button 1S Warn people to stay away from wheels and moving or lifting parts Never exceed specified max speed cargo or passenger capacity installed this label 1s required located Drive slowly on ramps in turns in reverse Avoid loose cargo Before turning on key switch and while moving be sure that under push button 3 109800006 occupants re Cin
30. es and fittings for leaks gt SRE ii 14 Maintenance DEADMAN SEAT BRAKE Maintenance work must be performed by trained personnel only Before any maintenance work turn key switch to off and disconnect battery terminal LUBRICATION Grease the spherical rod end two pillow blocks and brake cable arm CHECK BRAKE PAD Minimum brake pad wear is 1 8 inch 3 mm SEAT ADJUSTMENT 1 Unscrew the jam nut on the spherical rod end of the push rod under the seat 2 Unscrew the push rod until a 1 8 inch 3mm gap remains between the pivot and the spring rods see figure A 3 Tighten the jam nut SPRING ADJUSTMENT Tighten the spring adjustment rods until they exceed the bracket by two inchs 50 mm as shown on figure B BRAKE PADS ADJUSTMENT 1 Slide the seat fully rearward 2 Unscrew the jam nut on the brake cable adjustment bolt on the outer brake pad 3 Unscrew the adjustment bolt to increase brake pressure 4 The springs must be able to apply the parking brake when the seat is raised slowly 5 Check the deadman seat switch it must be activated when the seat is raised 6 Tighten the jam nut 1 2 5 2 4 3 4 9 TT T PC S 7 a I fi 7 T i g g 1 TI Ly h Li lt 7 k sh 2 44 c gt NES VAS ga E A VANA Sim N
31. everse check wire open CONT DRVR OC cont driver output overcurrent 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 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 lt undervoltage cutback limit Corroded battery terminal Loose battery or controller terminal OVERVOL TAGE overvoltage Battery voltage gt overvoltage shutdown limit Vehicle operating with charger attached Battery disconnected during regen braking THERMAL CUTBACK over under temp cutback Temperature gt 85 C or lt 25 C Excessive load on vehicle Improper mounting of controller Operation in extreme environments ANTI TIEDOWN Curtis PMC 1244 Manual Mode 2 or Mode 4 selected at startup 26 Mode switches shorted to B 2 Mode switches tied down to select Mode 2 or Mode 4 permanently 78 8 DIAGNOSTICS amp TROUBLESHOOTING LED DIAGNOSTICS A Status LED is built into the 1244 controller It is visible through a windo
32. he 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 15 ISOLATED FOR HIGH VOLTAGE APPLICATIONS DO NOT USE THE CHASSIS FOR GROUND 44 Spare Parts BATTERY DISCHARGE INDICATOR HOBBS This indicator monitors the residual capacity of batteries operating hours status of service down counter The residual capacity of the battery is monitored via an 8 LED bar display When the left red LED lights the batteries must be charged to avoid damage The LED display starts flashing as a pre warning signal The lower voltage limit is adjustable via potentiometer 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 15 recommended to limit the discharging to 80 of the battery capacity The recommended setting for 6V batteries 15 F and the recommended setting for 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 fo
33. ing or replacing a battery charger speed controller contactor relay diode or any other component in the power circuit always disconnect the charger turn off all switches remove the key wear a face shield and gloves identify battery polarity and disconnect battery leads discharge the capacitor in the controller with a 10 ohms 25 W resistor for a few seconds across B and B After cleaning the power must not be reapplied until terminal areas are thoroughly dry On EE Rated vehicles make sure that the control box is sealed the static strap makes good contact with the ground the motor 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 filt
34. is at the last position on the left the batteries must be recharged A flashing light warns the operator that further discharge will damage batteries See HOBBS indicator instructions EMERGENCY SAFETY DEVICE The emergency push button or battery disconnect handle when present should only be used in case of emergency Use the key switch for normal ON OFF control KEYSWITCH Depress brake pedal and turn the key switch clockwise for on position Always turn off all switches set the F R selector to neutral set the parking brake remove the key before leaving the vehicle HORN Depress the horn button on the steering column or handle bar F R SWITCH Three positions with neutral at center Depress the front part of the rocker switch for forward direction Depress the rear part of the rocker switch for reverse direction Always set switch to neutral turn off all switches set the parking brake remove the key before leaving the vehicle ACCELERATOR PEDAL It is designed for right foot operation only and controls the speed of the vehicle Apply slowly FOOT BRAKE PEDAL It is designed for right foot operation only The brake force is proportional to the pressure on the pedal PARKING BRAKE Pull handbrake lever to apply Never park the vehicle on an incline Always turn off all switches set the F R selector to neutral set the parking brake remove the key before leaving the vehicle Maintenance MAINTENANCE Maintenance SAFE
35. isconnect 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 if not B replace the key switch Check voltage across DC DC converter output terminals if not 12 Volt replace the converter Depress the accessory switch check voltage across accessory terminals If not 12 Volt replace the switch If 12 Volt replace the accessory FORWARD ONLY On a SEPEX motor control check the reverse signal input on the controller On a series wound motor control a bad reverse contactor is the most probable cause of the problem Switch to reverse and check voltage on the reverse control wire If not B replace the F R switch If B turn off the ke
36. l battery CHARGING AREA Always charge battery a well ventilated area set for and approved for charging Never leave a charger connected for more than 20 hours FREQUENCY OF CHARGE When a battery is discharged to its 20 state of charge it is best to charge immediately Batteries require a low current equalization charge min 4 hours at least every week to equalize battery cells improve battery performance and life in number of cycles Never leave a charger connected for more than 20 hours STORAGE Keep the battery from getting cold it would loose its capacity 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 is shorted voltage drop may occur only when there 15 current 17 Maintenance ELECTRICAL TROUBLESHOOTING WARNING Maintenance work must be performed by trained service technicians only It is the responsibility of the owner of this vehicle to ensure that the services technicians are properly trained understand and obey the safety rules and guidelines ANSI B56 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 d
37. r 30 sec The current status remaining operating hours before maintenance of the service down counter is indicated for a period of 5 seconds after the key switch is turned on When it is down to U 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 3069038 48V UNIT 4869037 2 Orange key switch 3 Relay 4 Relay 5 Black battery 6 Blue hour counter 8 White battery 45 Addendum ADDENDUM 46 Addendum CURTIS FOOT PEDAL 2262005C 2262001C lt it 2262004C 2262003C PART NO DESCRIPTION 3062001C ACCELERATOR CURTIS 367008 POTENTIOMETER 2262004C SPRING 2262001C MICRO SWITCH 2262003C LEVER 3662002 CABLE PROTECTOR RESP CLAUDE L MODELLE T 224 236 248 NO _ 235422400 47
38. seated with seat belt bucked 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 When a disconnect handle is installed this label is required located in front of handle 4800012 BATTERY DISCONNECT PULL gt Respectively key switch markings forward reverse selector markings and light switch marking e e 266211 2819321003 1269004 10 Maintenance PERIODIC MAINTENANCE CHECKLIST REVISION 080206 WARNING Maintenance operations must be made by properly trained service technicians Keep clear from moving parts such as tires sheaves and motor Check for all EE protections when applicable and keep cables and wires clear from mechanical and rubbing action Batteries contain sulphur acid that can cause severe burns on skin or eyes When working around batteries wear acid proof protective equipment face shield and gloves 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
39. the circuit breaker If not 0 ohms replace the circuit breaker Check PMC First disconnect battery B and B then PMC B and M Check the internal diode between B and M terminals using a diode tester If no such instrument is at hand use an ohmmeter the reading should be weak in one direction and strong in the other way If the internal diode is defective the PMC must be replaced Check the Motor First disconnect battery B and B disconnect power terminals and check the motor armature and field for opens 20 Curtis Speed Controller CURTIS SPEED CONTROLLER 21 MANUAL CURTIS iil 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 22 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 5 914 666 2971 Fax 914 666 2188 CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE CALIFORNIA 94550 USA 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 Dia 2 INSTALLATION amp WIRING Controller WIRING Standard Configuration Figure 3 shows the typical wiring configuration for most applic
40. 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 25 77 8 DIAGNOSTICS amp TROUBLESHOOTING Table5 TROUBLESHOOTING CHART PROGRAMMER LCD DISPLAY FAULT 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 Emergency r
41. tors 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 SY1200 25 has a very advanced control section and will determine when to open the fuse An open fuse will mean that a problem had occurred that does not mean that the problem still exists or that the problem has gone away lt lt DO NOT increase or by pass the fuse USE ONLY A FUSE RATED AT 250V 20A gt gt 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 AMP 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 t
42. ts 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 which means the problem is either in the forward switch or
43. ughly 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 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 is more prone to short out BATTERY DISCHARGE LIMIT Discharging below a 20 state of charge cuts down the battery life and the number of cycles available At 20 state of charge specific gravity of 6V battery should be 1180 and 1220 for industria
44. ulb Mark 2569001 2569001B 4469001 3111480003 3111480004 3111480006 3111480008 3111480007 Headlight Left Right Bulb H L Bulb Turn Bulb Mark p 3111480003 3111480004 3117480001 3117480003 3117480002 Horn button VIP 2330014 Horn button column mount 246210 Horn button dash mount 266210 LC 3109250001 Turn signal switch 246050 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 42 Spare Parts BATTERY CAPACITY Analog Voltmeter 12V 24V 36 48V 3069007 2469002 3669002 HOBBS Gauge 24V 2469026 36V 3069038 48 4869037 DC DC converter 10A 12 48V 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 12 Dome light 12V Fan 3669013 43 Headlamp 12V 3111300001 Bulb 12V 3111300002 Red Pilot light 12V 246212 Bulb 12V 246212B e
45. w in the label on top of the controller This Status LED displays fault codes when there isa problem with the controller or with the inputs to the controller During normal operation with no faults present the Status LED flashes steadily on and off If the controller detects a fault a 2 digit fault identification code is flashed continuously until the fault is corrected For example code 3 2 welded main contactor appears as OOD 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 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 IONE gt gt 0 1 1 1 1 gt 2 2 2 3 3 3 3 4 4 4 4 NOTE Only one fault is indicated at a time and faults are not queued up Refer to the troubleshooting chart
46. y 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 power terminals If not 0 ohms change the forward contactor 18 Maintenance REVERSE ONLY On a SEPEX motor control check the forward signal input on the controller On a series wound motor control a bad forward contactor is the most probable cause of the problem Switch to forward and check the voltage on the forward control wire If not B replace the F R switch If 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
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