MAINTENANCE MANUAL
Contents
1. Always charge battery in a well ventilated area set for and approved for charging Never leave a charger connected for more than 20 hours FREQUENCY OF CHARGE When a battery is discharged to its 20 state of charge it is best to charge immediately Batteries require a low current equalization charge min 4 hours at least every week to equalize battery cells improve battery performance and life in number of cycles Never leave a charger connected for more than 20 hours STORAGE Keep the battery from getting cold it would loose its capacity 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 is current 14 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 disconnect charger Alw2. Respectively key switch markings forward reverse selector markings and light switch marking Q REV Maintenance PERIODIC MAINTENANCE CHECKLIST WARNING Maintenance operations must be made by properly trained service technicians Keep clear from moving parts such as tires sheaves and motor Check for all EE protections when applicable and keep cables and wires clear from mechanical and rubbing action Batteries contain sulphur acid that can cause severe burns on skin or eyes When working around batteries wear acid proof protective equipment face shield and gloves Use electrically insulated tools to avoid sparks that can cause battery explosion Before any maintenance work park the vehicle on a flat level surface turn off all switches remove the key lift the wheels off the ground and secure with jack stands of adequate capacity identify and disconnect battery leads Don t connect the charger MECHANICAL DAMAGE OIL LEAKS X REVERSE ALARM DEADMAN SWITCH IX STATIC STRAP min 2 contact with ground TIRE PRESSURE pressure rating on tire X CHECK FILL BATTERIES add distilled water to cover plates Fill to recommended level after batteries have X been fully charged WARNING DECALS amp MARKINGS X EE Rated CABLE PROTECTORS SEALED MOTOR mur SEALED CONTROL BOX MASTER CYLINDER FLUID DOT3 X 2 50 mm ma
3. 41
4. SAFETY WARNINGS FOR OPERATORS MAINTENANCE SAFETY WARNINGS FOR SERVICE TECHNICIANS DECALS AND LABELS PERIODIC MAINTENANCE CHECKLIST BELT INSTALLATION AND TENSIONING HYDRAULIC BRAKES BATTERY MAINTENANCE ELECTRICAL TROUBLESHOOTING CURTIS SPEED CONTROLLER WIRING STANDARD CONFIGURATION DIAGNOSTICS AND TROUBLESHOOTING TROUBLESHOOTING CHART LED DIAGNOSTICS PROGRAMMING PARAMETERS T 224 224D SPARE PARTS BODY DIFFERENTIAL BRAKE CONTROLS STEERING WHEEL MOTOR AND DRIVE ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT ACCESSORIES DC DC CONVERTER MOTREC ILLUSTRATED ACCESSORIES CONVERTER INSTALLATION BATTERY DISCHARGE INDICATOR HOBBS ADDENDUM CURTIS FOOT PEDAL Instructions INSTRUCTIONS Instructions SAFETY WARNINGS FOR OPERATORS e FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY e 15 the responsibility of the owner of this vehicle to train operators to ensure that they understand the operating characteristics of this vehicle including training in vehicle stability and obey the following safety rules and guidelines Owner shall comply with OSHA and ASME 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 Do 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 bui
5. B56 9 regulations for vehicle maintenance Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect carriers vehicles tractors and batteries Before any maintenance work park the vehicle on flat level surface turn off all switches remove key lift wheels off the ground and secure with jack stands of adequate capacity Don t connect charger Keep clear from moving parts such as tires sheaves and motor Follow the maintenance instructions applicable to the type of repair maintenance or service Always wear a face shield and gloves when working around batteries Before opening the battery compartment disconnect the charger turn off all switches and remove the key Batteries emit highly explosive gases which greatly increase when charging do not disturb connections or produce sparks around batteries to avoid a battery explosion and acid splashing Battery acid causes severe damage to eyes or skin Flush contaminated area immediately with water Use insulated tools to avoid sparks that can cause battery explosion and acid splashing Use two counteracting tools double wrench technique when disconnecting or tightening terminals on the battery and the speed controller to avoid cracking the terminal or battery post welds Before cleaning or replacing a battery charger speed controller contactor relay diode or any other component in the power circuit always disconnect the charger turn off
6. Contactor coil shorted MAIN CONT WELDED welded main contactor 1 Main contactor stuck closed 2 Main contactor driver shorted HARGE FAULT MISSING CONTACTOR internal voltage too low at startup missing contactor 1 Controller defective 2 External short or leakage path to B on external B connection 1 Any contactor coil open or not connected MAIN CONT DNC LOW BATTERY VOLTAGE OVERVOLTAGE main contactor did not close low battery voltage overvoltage 1 Main contactor missing or wire to coil open 1 Battery voltage lt undervoltage cutback limit 2 Corroded battery terminal 3 Loose battery or controller terminal 1 Battery voltage gt overvoltage shutdown limit 2 Vehicle operating with charger attached 3 Battery disconnected during regen braking THERMAL CUTBACK over under temp cutback 1 Temperature gt 85 C or lt 25 C 2 Excessive load on vehicle 3 Improper mounting of controller 4 Operation in extreme environments ANT I TI EDOWN Curtis PMC 1244 Manual Mode 2 or Mode 4 selected at startup 293 1 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 window in the label on top of the controller This Status LED displays fault code
7. Speed Controller PROGRAMMING PARAMETERS 224 2240 WARNING The owner of this vehicle shall ensure that the service technicians are qualified properly trained and obey the safety rules and guidelines in OSHA and ANSI B56 regulations and in this manual Before installing and or programming the PMC park the vehicle on a flat level surface lift the wheels off the ground and secure with jack stands of adequate capacity Don t connect charger Programmable controllers must be programmed using the parameter settings in this service manual before connecting the motor to avoid sudden vehicle movement and accident Do not try to increase motor speed by changing parameter settings in the speed controller it can cause accident and severe damage to the motor VOLTAGE M1 DRIVE C L M2 DRIVE C L M3 DRIVE C L M4 DRIVE C L M1 BRAKE C L M2 BRAKE C L M3 BRAKE C L M4 BRAKE C L M1 THRT BRK M2 THRT BRK M3 THRT BRK M4 THRT BRK M1 ACCEL RATE M2 ACCEL RATE M3 ACCEL RATE M4 ACCEL RATE DECEL RATE M1 BRAKE RATE M2 BRAKE RATE M3 BRAKE RATE M4 BRAKE RATE QUICK START TAPER RATE M1 MAX SPEED M2 MAX SPEED M3 MAX SPEED M4 MAX SPEED M1 CREEP SPEED M2 CREEP SPEED M3 CREEP SPEED M4 CREEP SPEED REGEN SPEED CTRL MODE THROTTLE TYPE REF NOMINAL BATTERY VOLTAGE IN VOLTS EB MODE 1 DRIVE CURRENT LIMIT IN AMPS 300 MODE 2 DRIVE CURRENT LIMIT IN AMPS 300 MODE 3 DRIVE CURRENT LIMIT IN AMPS 300 MODE 4 DRIVE CU
8. all switches remove the key wear a face shield and gloves identify battery polarity and disconnect battery leads discharge the capacitor in the controller with a 10 ohms 25 W resistor for a few seconds across B and B After cleaning the power must not be reapplied until terminal areas are thoroughly dry On EE Rated vehicles make sure that the control box is sealed the static strap makes good contact with the ground the motor is sealed by bands the cable protectors are properly installed Keep cables and wires clear from mechanical and rubbing action Make sure that cable insulation 15 free from cutting or visible damage Make sure that EE Rated cable protectors are properly installed Before replacing a fuse or circuit breaker identify the cause of failure and repair Programmable controllers must be programmed using the parameter settings in this service manual before connecting the motor to avoid sudden vehicle movement and accident Maintenance Do not try to increase motor speed by changing parameter settings in the speed controller it can cause accident and severe damage to the motor SEPEX speed controls are protected by a diode in the power circuit to filter inductive loads in the event of a sudden power interrupt Some speed controllers require a diode to filter inductive loads on the KSI input Removing the diodes will cause the speed control failure Before resuming maintenance operations inspect safety warnings st
9. 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 is F and the recommended setting for an industrial battery is K An internal relay can prevent overdischarging and damaging the batteries The relay can be wired to cut off the reverse 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 is 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 3069038 48V UNIT 4869037 2 Orange key switch 3 Relay 4 Relay 5 Black battery 6 Blue hour counter 8 White battery 39 Addendum ADDENDUM 40 Addendum CURTIS FOOT PEDAL 8 22620050 22620030 4 22620010 22620040 367008 PART NO DESCRIPTION 3062001C ACCELERATOR CURTIS 367008 POTENTIOMETER 2262004C SPRING 22620010 MICRO SWITCH 2262003C LEVER 3662002 CABLE PROTECTOR RESP CLAUDE L MODELE T 224 236 248 235A224001
10. 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 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 38 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 C D JF J K 1 89 1 93 In order to activate a new adjustment the unit has to be reset 2 35V
11. 0V 2469001 Blue 12 80V 3690008 Strobelight cab mount Amber 12 48V 3116250001 Red 12 48V 3069026 Blue 12 48V 3069014 Amber 72 80V 3116720001 Red 72 80V 3116720002 Blue 72 80V 3116720003 Amber turn lamp 12V 3069020 Bulb 12V 3069021 Red Tail Brake light Grommet 3269001 Plug 246012A 12V 2469021 24V 2469022 Red Tail Brake light 12V 386002 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 Bulb Mark 2569001 2569001B 4469001 3111480003 3111480004 3111480006 3111480008 3111480007 Headlight Left 3111480003 Right 3111480004 Bulb H L 3117480001 Bulb Turn 3117480003 Bulb Mark 3117480002 Turn signal switch 246050 11111 Lj 41214118 Analog Voltmeter 2 3069007 24V 2469002 36 48V 3669002 11111313 HOBBS Gauge 24V 2469026 36V 3069038 48V 4869037 Horn 12V 246003 24V 246013 36 Horn button VIP 2330014 Horn button column mount 246210 Horn button dash mount 266210 Horn button 3109250001 Limit switch 3030015 Back up alarm 12 48V 72 80V 3100000001 3105720001 Spare Parts DC DC con
12. 30 150 50 ON ON ON OFF OFF OFF OFF OFF 100 100 OFF 50 OFF OFF ON OFF ON Spare Parts SPARE PARTS 96 Spare Parts BODY REF NUMERO DESCRIPTION 6105236001 BODY 2 2355236001 ROLLER 2356236001 SHAFT ROLLER 2200010 BEARING 3 2311000006 RUBBER BUMPER 16 4 283001 4 8X8 LRC WHEEL 2807001 BLACK SOFT RUBBER WHEEL 2807007 RIB GREY SOFT RUBBER WHEEL 2450001 STATIC STRAP 5 900 2595 FLOOR MAT ADHESIVE 6 2200018 PIN ROLL OUT 2662002 SPRING PIN ROLL OUT 7 2500250002 DASHBOARD 8 2205002 GRAMMER SEAT WITH SWITCH 27 Spare Parts DIFFERENTIAL Z 7 48 43 44 gt 4 227177 4 VAL mgt MT 5 48 uc MAL 28 Spare Parts REF N 12 13 14 15 16 17 18 19 20 21 22 23 24 OG 28 29 30 31 32 33 34 35 36 37 38 39 42 43 44 45 46 47 48 PART NO 481433 2173236001 242053 242054 481430K 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 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 M
13. AND CONNECTORS Check for loose connections damaged cables acid spill loose terminal posts quarterly BATTERY POST CORROSION If corrosion is present on battery posts remove the cable connectors use a wire brush to remove particles and then clean them with a cloth that has been moistened with ammonia ELECTROLYTE LEVEL Does not apply to sealed battery Disconnect battery connectors on roll out or lift out installations Make sure the battery roll out tray is provided with stops before rolling out Fill with distilled water Daily charged batteries normally require watering once a week Under watering leads to a shortened battery life Over watering leads to battery corrosion Be careful not to overfill any cell to avoid electrolyte to be forced out while charging Fill each cell to plate level with distillated or de 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 13 Maintenance BATTERY MOUNTING A loose battery increases damaging effects of vibrations and is more prone to short out BATTERY DISCHARGE LIMIT Discharging below a 20 state of charge cuts down the battery life and the number of cycles available At 20 state of charge specific gravity of 6V battery should be 1180 and 1220 for industrial battery CHARGING AREA
14. ECTRICAL DIAGRAM SEPEX MAIN CIRCUIT DIAGRAMME ELECTRIQUE CIRCUIT PRINCIPAL SEPEX OSAHIDUVHI ON PPZL XAd3S ONIMYUO X3d3IS LINDHID NIYIN d39HVvH2 ON FFE X3d3S 234 LON oaran 199v 034 HALHA LHM 33 OSA 20 00 20 daA0H4dY NONDYOT 4OHLNY LI PO 9002 LO NOISH3A HSLYSANOD 90 90 de JOLTSHTLLIHE 99 QSULOW A1233r8ns Spare Parts ACCESSORIES DC DC CONVERTER ACCESSOIRES CONVERTISSEUR DC DC OW GRN BLE LHM 34 Spare Parts PARTS LIST 244 4451 246108K F 3107000002 F P 2 1 2 3 1 DIODE BRIDGE 3669027 1 1 1 3 8 2 BATTERY SEPEX MOTOR COOLING FAN 12 3129224001 lt METER BATTERY GAUGE R ACCELERATOR CURTIS POTENTIOMETER 367008 SPRING 22620040 MICROSWITCH 22620010 LEVER 22620030 SI KEYSWITCH 246205 S3 SEAT SWITCH MICRO SWITCH 3109100002 SEAT SWITCH SEAT MOUNTED 366216 366212 58 LIGHT SWITCH ROCKER TYPE 1269004 3669004 3109800001 N 5 5 5 5 EMERGENCY PUSH BUTTON LABEL 3109800006 246112 HEAVY DUTY MAIN CONTACTOR GE800AH205XO STATICSTRAP 12450001 Consult Motrec illustrated parts 92 ON O 25 Spare Parts Strobelight polemount Amber 12 80V 3116000001 Red 12 8
15. F 17 18 19 21 22 23 24 25 26 27 28 29 31 PART NO 2110248002 2203248001 2102124001 201434 2229300002 2103300003 2224300002 2103300005 2910300002 2229300001 2230023 366221 2361001 366212 800 DESCRIPTION CHAIN 40 1 2 FORK BEARING WASHER OIL SEAL BEARING HUB BEARING JAM NUT I 1 4 NF DUST CAP CASE F R GREY HANDLE NAMEPLATE F R SWITCH CONTACT BLOC Spare Parts MOTOR AND DRIVE AA ra LAA NE 15 COMMON PARTS REF DESCRIPTION PART RE DESCRIPTION PART 1 PULLEY 262424 8 MOTOR BASE FORD Contact manuf 2 V BELT 242431 BELT TENSIONER 2152002 3 PULLEY 365100 1 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 00 DOOSEPEX SEPEX DANA DRIVE MOTOR ASS Y 484000 204050 2950002 2450003 3112210001 3122230001 13 BRUSH SPRING 484010 484010 2450006 2450006 2450006 2450006 14 BRUSH PLATE 484011 1484011 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 32 Spare Parts EL
16. MOTREC iw 1 2240 AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1039902 amp UP Printed in Canada One Year Limited Warranty Effective April 25 2005 MOTREC Inc MOTREC hereby warrants to the Original Retail Purchaser Owner that any of its vehicles shall be free from any defect in materials for a period of 90 DAYS while 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
17. NABLE EM BRAKE AUX DELAY AUX CHECK EM BRAKE DELAY EM BRAKE CHECK REV DRVR CHECK CONT PULL IN CONT HOLDING EMR REV ENABLE EMR REV C L EMR REC CHECK ANTI TIEDOWN FAULT CODE PEDAL INTERLOCK PRECHARGE Thr Neutral deadband of 5kohms Thr Input reg d for 100 PWM 5kohm pot MODE 1 THROTTLE MAP AS MODE 2 THROTTLE MAP AS MODE 3 THROTTLE MAP AS MODE 4 THROTTLE MAP AS MIN FIELD CURRENT IN AMPS MAX FIELD CURRENT IN AMPS Armature current at wich FIELD MAP takes effect amps Field Winding Current as of Armature Current CURRENT RATIO FACTOR OF 1 2 4 OR 8 RAMP RESTRAINT 1 TO 10 LOAD COMPENSATION 0 TO 25 HIGH PEDAL DISABLE HPD TYPE STATIC RETURN TO OFF SRO TYPE SEQUENCING DELAY IN SEC MAIN CONTACTOR INTERLOCK ON OR OFF MAIN CONTACTOR DROPOUT DELAY IN SEC MAIN CONTACTOR WELD CHECK ON OR OFF MAIN COIL OPEN CHECK ON OR OFF AUXILIARY ENABLE ON OR OFF ELECTROMAGNETIC BRAKE ON OR OFF AUXILIARY DRIVER DROPOUT DELAY IN SEC AUXILIARY COIL OPEN CHECK ON OR OFF ELECTROMAGNETIC BRAKE DELAY IN SEC ELECTROMAG BRAKE OPEN CHECK ON OR OFF REVERSE SIGNAL OPEN CHECK ON OR OFF CONTACTOR COIL PULL IN VOLTAGE AS CONTACTOR HOLDING VOLTAGE AS EMERGENCY REVERSE FUNCTION ON OR OFF EMERGENCY REVERSE CURRENT LIMIT AMPS EMERGENCY REV WIRING CHECK ON OR OFF ANTI TIEDOWN ON OR OFF ON OR OFF THREADLE PB 6 CHECK WIRING ON OR OFF o 90 30 30 30 30 7 5
18. OUNTING 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 29 Spare Parts BRAKE CONTROLS REF PARTS NO 242801 2131248001 2132248002 2190000003 122813 2133300001 2125000001 2135248001 ONU R DESCRIPTION RUBBER BRAKE LEVER PIVOT SPRING YOKE 3 8 ROD MASTER CYLINDER SUPPORT OTY N e NO ma R F PARTS NO 9 10 11 12 13 14 15 16 30 3616013 2416009 362831A 2316005 3616014 362832 3616015 362833 DESCRIPTION HANDBRAKE YOKE CABLE HANDBRAKE PAD HANDBRAKEPAD CLIP SPRING CABLE STOPPER OTY Spare Parts 2 CHINESE y WN STEERING WHEEL PART NO 2330014 2330013 2230014 HBK 2200224004 2330015 2230015 2230016 2230017 2200224003 2809000001 2200248002 2200224002 231404 2330012 2110248001 2205248001 DESCRIPTION HORN BUTTON STEERING WHEEL HORN BRUSH KIT TILT TEL COLUMN UNIVERSAL JOINT SUPPORT WASHER BUSHING SHAFT RUBBER BOOTS NYLON COUPLER SHAFT UNIVERSAL JOINT PIVOT CHAIN 46 FRONT PIVOT E R
19. RRENT LIMIT IN AMPS 300 MODE 1 BRAKING CURRENT LIMIT IN AMPS 150 MODE 2 BRAKING CURRENT LIMIT IN AMPS 150 MODE 3 BRAKING CURRENT LIMIT IN AMPS 150 MODE 4 BRAKING CURRENT LIMIT IN AMPS 150 MODE 1 THROT BRAKING AS OF BRAKE C L MODE 2 BRAKING AS OF BRAKE C L O1 O MODE 3 BRAKING AS OF BRAKE C L MODE 4 THROT BRAKING AS OF BRAKE C L MODE 1 ACCELERATION RATE IN SEC MODE 2 ACCELERATION RATE IN SEC MODE 3 ACCELERATION RATE IN SEC MODE 4 ACCELERATION RATE IN SEC 19 DECELERATION RATE IN SEC MODE 1 BRAKING RATE IN SEG MODE 2 BRAKING RATE IN SEG MODE 3 BRAKING RATE IN SEC MODE 4 BRAKING RATE IN SEC QUICK START THROTTLE FACTOR Regen brak Decrease rate when apporch Ospd 1 325 MODE 1 SPEED AS PWM OUTPUT A MODE 2 MAX SPEED AS PWM OUTPUT MODE 3 MAX SPEED AS PWM OUTPUT MODE 4 MAX SPEED AS PWM OUTPUT MODE 1 CREEP SPEED AS PWM OUTPUT MODE 2 CREEP SPEED AS PWM OUTPUT MODE 3 CREEP SPEED AS PWM OUTPUT MODE 4 CREEP SPEED AS PWM OUTPUT Min speed for regen braking as of vehicle speed 25 CONTROL MODE THROTTLE TYPE 1244 0510401 THRO DEADBAND THROTTLE MAX M1 THRTL MAP M2 THRTL MAP M3 THRTL MAP M4 THRTL MAP FIELD MIN FIELD MAX FIELD MAP START FIELD MAP CURRENT RATIO RESTRAINT LOAD COMP U T P SRO SEQUENCING DLY MAIN CONT INTR MAIN OPEN DELAY WELD CHECK MAIN CHECK AUX E
20. ays 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 the battery gage if not B replace the key switch Check voltage across DC DC converter output terminals if not 12 Volt replace the converter Depress the accessory switch check voltage across accessory terminals If not 12 Volt replace the switch If 12 Volt replace the accessory FORWARD ONLY On a SEPEX motor control check the reverse signal input on the controller On a series wound motor control a bad reverse contactor is the most probable cause of the problem Switch to reverse and check voltage on the reverse control wire If not B replace the F R switch If B turn off the key switch disconnect ba
21. ch is typically a seat switch tiller switch or foot switch Standard Power Wiring Motor armature winding is straightforward with the armature s Al connection going to the controller s B bus bar and the armature s A2 connection going to the controller s M bus bar The motor s field connections F1 and F2 to the controller are less obvious The direction of vehicle travel with the forward direction selected will depend on oJ og CONTACTOR COIL FORWARD REVERSE 5 0 THROTTLE TYPICAL MODE SELECT 2 MODE SELECT 1 INTERLOCK KEYSWITCH MAIN CONTACTOR PROTECTION DIODE CONTROL FUSE Fig 3 Standard wiring configuration Curtis PMC 1244 controller Curtis PMC 1244 Manual 221 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 Faults are displayed in the Diagnostic Menu see column 2 in t
22. e 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 205 8 DIAGNOSTICS amp TROUBLESHOOTING Table5 TROUBLESHOOTING CHART LED CODE PROGRAMMER LCD DISPLAY HW FAILSAFE1 2 3 FAULT CATEGORY self test or watchdog fault 1 Controller defective M SHORTED internal M short to B 1 Controller defective FIELD OPEN field winding fault 1 Motor field wiring loose 2 Motor field winding open ARM SENSOR armature current sensor fault 1 Controller defective FLD SENSOR THROTTLE FAULT 1 THROTTLE FAULT 2 field current sensor fault wiper signal out of range pot low fault 1 Controller defective 1 Throttle input wire open 2 Throttle input wire shorted to B or B 1 Throttle pot defective 2 Wrong throttle type selected SRO SRO fault HPD fault 1 Improper sequence of KSI interlock and direction inputs 2 Wrong SRO type selected 3 Interlock or direction switch circuit open 4 Sequencing delay too short 1 Improper seq of direction and throttle inputs 2 Wrong HPD type selected 3 Misadjusted throttle pot 4 Sequencing delay too short BB WIRING CHECK emergency reverse wiring fault 1 Emergency reverse wire open 2 Emergency reverse check wire open CONT DRVR OC cont driver outp ut overcurrent 1
23. eed dragging brakes cold temperature higher differential oil viscosity INTERMITTENT OPERATION A bad potentiometer is the most probable cause of the following acceleration is not constant maximum speed is erratic sudden stop after a bump or shock erratic starts requiring several pedal cycles A bad F R contactor is also a probable cause of the following sudden stop after a bump or shock would not start to move at times Erratic starts could also be the cause of a misadjusted potentiometer or micro switch the pot signal must be less than 50 ohms when the micro switch turns on PMC has an HPD safety feature that prevents the vehicle from moving if the accelerator pedal is depressed before the key switch is ON and seat switch is activated PMC may also have an SRO safety feature that prevents the vehicle from moving if the F R switch is activated before turning on the key switch and activating the seat switch The vehicle stops on a steep and long ramp or while towing a heavy load the circuit breaker has open to prevent motor overheating and will reset automatically after one minute The PMC is also equipped with an internal thermal protection that cutback the current until the PMC has cooled down 216 Maintenance NO MOTION Make sure that the PMC surface is clean and dry check the terminal areas Dust Particles or acid contamination can create current leaks and cause a PMC malfunc
24. he 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 24 04 2006 Table of contents TABLE OF CONTENTS INSTRUCTIONS
25. he 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 STEP 3 Select the Test Menu and observe the status of the inputs and outputs in the forward direction In this example the display shows that the forward switch did not close when forward was selected which means the problem is either in the forward switch or the switch wiring STEP 4 Check or replac
26. ickers and replace any if damage is found and part of the text can t be read Maintenance DECALS AND LABELS CAUTION The images included in this section depict the decals markings installed on the vehicle It is of the utmost importance that theses decals markings remain unaltered and readable Else the sticker or the part baring the marking has to be replaced Dashboard security warning label Operation of this vehicle is restricted to authorized persons only Head operator s instructions in owner s manual prior to driving General security warning label Operation of this vehicle is restricted to authorized persons only Head operator s instructions in owner s manual prior to driving Do not operate on roads public streets and unauthorized areas Mever 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 attact Before leaving this vehicle park on a flat surface set to neutral set the parking brake turn off all switches and remove the key
27. ldings 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 carry cargo that is longer wider or higher than this vehicle e Always depress slowly the accelerator for smooth acceleration Avoid stunt driving or horseplay e Avoid sharp turns always slow down before turning to prevent vehicle overturn or trailer jack knife Vehicle is more sensitive to overturn and jack knife when traveling on inclines or when carryi
28. nd 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 15 158 then lengthen centre distance C F SPAN LENGTH F FORCE 185 DEFLECTION IN C CENTER DISTANCE IN 11 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 is released DISC BRAKES Check pad linings for excessive wear the linings should have a thickness exceeding 1 16 1 5 mm Disc brakes are self adjusting BRAKE PEDAL If the brake pedal becomes soft or spongy air may have entered the hydraulic system and the brake system has to be bled 1 2 QE 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 i
29. ng 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 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 uses brakes when you slow or stop the towing vehicle Do not exceed 5 MPH or carry any passenger while towing this vehicle er Maintenance MAINTENANCE Maintenance SAFETY WARNINGS FOR SERVICE TECHNICIANS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY Owner shall comply with OSHA and ASME ANSI B56 8 amp
30. nspect brake lines and fittings for leaks 212 Maintenance BATTERY MAINTENANCE WARNING Itis the responsibility of the owner of this vehicle to ensure that the service technicians are properly trained read and obey the safety rules and guidelines in this manual ANSI B56 Maintenance operations must be made by properly trained service technicians only Before any maintenance work park the vehicle on a flat level surface turn off all the switches set to neutral remove the key lift the wheels off the ground and secure with jack stands of adequate capacity Keep charger disconnected while doing any maintenance work Always wear a face shield and scarf when working around batteries Battery emits highly explosive gases do not produce sparks to avoid battery explosion and acid splashing Battery acid causes severe damage to eyes or skin Flush contaminated area immediately with water Use insulated tools to avoid sparks that can cause battery explosion and acid splashing Use two counteracting tools double wrench technique when disconnecting or tightening battery posts Before cleaning or replacing a battery discharge the capacitor in the controller with a 10 ohms 25 W resistor for a few seconds across B and B identify battery polarity and disconnect battery leads After cleaning the power must not be reapplied until terminal areas are thoroughly dry BATTERY LEADS
31. ow to reduce noise The converter must be mounted on a Ne metal surface for proper heat dissipation A 2 15 a vertical mounting position is best to maximize the I convection process The unit will shut down 5 0 thermally under high currents if not properly 9 99 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 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 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 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
32. place 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 17 Curtis Speed Controller CURTIS SPEED CONTROLLER 18 MANUAL 19 CURTIS 2701 1244 MultiMode MOTOR CONTROLLER 2001 CURTIS INSTRUMENTS INC DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 1244 Manual p n 16958 Rev B January 2001 1244 Manual p n 16958 Rev B January 2001 2001 CURTIS INSTRUMENTS ING CURTIS INSTRUMENTS ING 200 KISCO AVENUE MOUNT KISCO NEW YORK 10549 USA 914 666 2971 rax 914 666 2188 CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE CALIFORNIA 94550 USA 925 961 1088 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 20 2 INSTALLATION amp WIRING Controller WIRING Standard Configuration Figure 3 shows the typical wiring configuration for most applications The interlock swit
33. s 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 contactor appears as G a uuu a G 352 2 2 252 The codes are listed in Table 6 Table6 STATUS LED FAULT CODES LED CODES EXPLANATION LED off no power or defective controller solid on controller or microprocessor fault controller operational no faults not used hardware failsafe fault M current sensor or motor fault not used throttle fault static return to off SRO fault high pedal disable HPD fault emergency reverse circuit check fault contactor driver overcurrent welded main contactor precharge fault missing contactor or main cont did not close low battery voltage overvoltage thermal cutback due to over under temp anti tiedown fault Kobe Kobe kos ROUE 0 1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4 NOTE Only one fault is indicated at time and faults are not queued Refer to the troubleshooting chart Table 5 for suggestions about possible causes of the various faults Curtis PMC 1244 Manual 24 9 Curtis
34. tion Check F R switch Turn on the key switch and set to forward Check voltage between the forward terminal and the terminal on the battery gage check voltage between the reverse terminal and the terminal on the battery gage if both B replace the F R switch Check switches and wiring Disconnect control terminals on the PMC and check all control signals If a switch pin does not read B check wiring or replace the switch Check potentiometer Turn the key switch to OFF disconnect potentiometer terminals Check the resistance across terminals if not within the recommended limits adjust or replace the potentiometer Check for shorts between potentiometer wires and vehicle frame resistance should read at least 1 megohm 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 re
35. tteries disconnect power terminals on the F R contactors check the resistance across N C power terminals of the reverse contactor If not 0 ohm change the reverse contactor If 0 ohms switch to forward and check the resistance across the forward N O power terminals If not 0 ohms change the forward contactor 2155 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 Other causes of lower sp
36. verter 10 12 48V 3069019 7 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 2800000002 2800000003 Pantograph wiper arm 246233A Pantograph wiper blade 246233 Cab heater 12V 3103300001 36V 3669008 48V 4869020 amp 12V Dome light 3669006 12V Fan 3669013 37 Headlamp 12V 3111250002 il V TT 4 av W 47 1 t 4 3111300001 3111300002 Headlamp 12V Bulb 12V Red Pilot light 12V Bulb 12V 246212 246212B Spare Parts CONVERTER INSTALLATION Installation and Trouble Shooting Guide SY1200 25 The SY1200 25 is a state of the art DC DC 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 tne installation procedures for help The ORANGE wire is the INPUT POSITIVE gt The BLACK wire near the orange wire is the INPUT NEGATIVE gt The RED wire is the OUTPUT POSITIVE The BLACK wire near the red wire is the OUTPUT NEGATIVE NOTE Use the correct black wire for input and output Do not connect the black wires together The black wires are common however due to the high currents developed in this unit it is necessary to maintain proper electron fl
37. will be allowed for delays To initiate warranty coverage on any MOTREC vehicle the Dealer must complete and return the Sales Installation Report to MOTREC within 30 days after delivery to the Original Retail Purchaser or within 90 days after the delivery date to the Dealer which ever occurs first Failure to follow these procedures will result in considering the warranty coverage effective as of the shipment date from the factory The defective vehicle must be returned at the Owner s expense to an authorised MOTREC Dealer within 30 days after failure The Owner will not be charged for parts and labour required for warranty repairs which must be performed by an authorised MOTREC Dealer only The vehicle will be returned at the owner s expense The Warranty Claim Forms must be completed and returned with the defective part s to MOTREC within 30 days after repair was done No compensation will be allowed for damages caused by vehicle downtime It is the responsibility of the owner of the vehicle to make sure that the driver is properly trained and instructed in the safety features and operation of the vehicle including vehicle stability as required by OSHA and ANSI B56 Operators shall read understand and follow the safety and operating instructions in MOTREC Manual before driving the vehicle Operators shall not be permitted to drive the vehicle unless a complete and adequate training has been provided Driving a vehicle constitutes a hazard T
38. ximum travel STEERING FOR PLAY pp PARKING BRAKE LEVER requires 10 Ibs 5 kg force to apply BELTS AND PULLEYS 10 Ibs Skg force for 1 8 3mm deflexion pulleys alignment see procedure CLEAN TIGHTEN WIRETERMINALS WASH BATTERY TOP WITH WATER MOTOR BRUSHES FOR WEAR 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 STEERING ASSEMBLY as instructed BRAKE MECHANICAL LINKAGES for wear amp play BRAKE LININGS FOR WEAR 1 16 1 5 mm minimum lining thickness LUBRICATE brake pedal pivots steering column ball o joints and kingpins Before adding oil check oil seals for leaks FRONT WHEEL BEARINGSPLAY X TIGHTEN NUTS BOLTS electric terminals drive steering brakes suspension body X REPLACE DIFFERENTIAL OIL SAE 30 __ f CLEAN AND RE PACK FRONT HUBS OT SERVICE DIFFERENTIAL replace the three oil seals wheel bearings oil SAE 30 10 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 a
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