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1. HOURS 20 50 100 1000 MECHANICAL DAMAGE STABILIZERS SCISSOR WELDMENTS SCISSOR PIVOTS amp SNAP RINGS PLATFORM GUARDS EXTENDING DECK ELECTRIC DAMAGE X CABLE THROUGH SCISSOR TO UPPER BOX CABLE ON LIFTING CYLINDER UPPER CONTROL BOX LOWER CONTROL STATION STABILIZER LIMIT SWITCHES HYDRAULICS SYSTEM X CYLINDER AND DOWN VALVE BODY FOR LEAKS FLUID LEVEL AWE 32 OIL FILTER PRESSURE GAUGE OIL FILTER REPLACEMENT X SAFETY DECALS X CHECK IF MISSING CHECK IF LEGIBLE LUBRICATE X SCISSOR oon PUMP MOTOR BRUSHES FOR WEAR X BRUSHES MUST EXCEED HOLDERS BLOW OUT CARBON DUST CHECK TIGHTEN HYDRAULIC FITTINGS NUTS BOLTS TERMINALS SCISSOR PIVOTS amp SNAP RINGS CYLINDER PINS GUARDS TABLE 10 SCISSOR LIFT INSPECTION AND LUBRICATION SCHEDULE CAUTION If necessary replace only with similar grade bolt 29 Maintenance SCISSOR LIFT INSPECTION AND LUBRICATION WEEKLY LOG Check and Initial Every 15 Hours of USE or Weekly COMPONENT oy TT wma mmm reens T I TT K HYDRAULIG SYSTEM 1 Gheck Fluid Level 3 checkFitings j jp jjj scissor system 0 jjj 1 Gheck for Damage ll DRIVE AND LIFT MECHANISMS L L Ki 1 1 Steer
2. I C 1 i 348 1 4 48 L 4 11 12 Accessories Ground 79 Spare Parts 0 0 02 piojiueu 03345 1 1 25 25087 3 1056125 JeaJ JUDI 80 Spare Parts T MOTHR EC inc TITRE E 480SC HYDRAULIC SCHEMATIC 1 SPEED F vu un w gt _ 4 m F c P c 4 rm 81 Spare Parts BUILT IN PORTABLE 25A CHARGER CAPAG I TOR OG ELECTRONIC T KIT HEL HEATSINK ASSEMBLY WITH DIODES 5 T gt n WHITE OR RED C BLACK 2 OC COROSET q AC INPUT BLACK 3 o GROUNDED BATTERIES PLUG m 27 CORDSET FUSE AMMETER ASSEMBLY CASE GROUND Parts list for LESTRONIC II charger MODEL 09695 TYPE 48LC25 SET 115 VAC 60 Hz PART NO DESCRIPTION 097275 CASE ASSEMBLY 096965 TRANSFORMER ASSEMBLY 163545 HEATSINK ASSEMBLY WITH DIODES 041275 096645 ELECTRONIC TIMER ASSEMBLY RELAY 037355 023905 CAPACITOR 6 0 660 087765 FUSE ASSEMBLY 020285 BUSHING 7W 2 INSULATOR FOR CORDSETS 025065 CORDSET 085125 CORDSET DC N
3. REF PART DESCRIPTION 1 30620010 ACCELERATOR CURTIS 2 367008 POTENTIOMETER 3 2262004 SPRING 4 2262001 MICRO SWITCH 5 2262003C LEVER 6 3662002 CABLE PROTECTOR RESP CLAUDE L MODEL E E 320 360 480 500 NO 3214320001 SER 1018799 1019973 87
4. Kemove cover to access filter and filler cap Figure 19 Filter and Filler cap location Check and fill Hydraulic Reservoir 2 28 4 5 6 1 Lower platform completely Remove load from platform Raise platform high enough to engage maintenance lock see maintenance lock WARNING MAINTENANCE LOCKS MUST BE INSTALLED when maintaining or servicing machine with platform fully or partially extended Working through beams on scissors lifting device creates hazardous situation which could cause death or personal injury FOLLOW MAINTENANCE LOCKS PROCEDURE ON PAGE 3 THIS MANUAL Lower platform so that maintenance lock rest on pivot pin Remove cover then filler cap and check fluid in reservoir Fill to proper level Replace cap Replace cover Raise platform slightly and retract maintenance lock 45 Maintenance Hydraulic pump and motor Replacement 1 Disconnect positive and negative battery cable by pulling battery disconnect handle out 2 Tag and remove wires from hydraulic pump end motor assembly 3 Remove hydraulic hoses from pump In the following step the high pressure hydraulic line may still be under pressure and fluid will squirt out when line is disconnected Do not reuse fluid as it may become contaminated Pump inlet quick valve do not close while pump is operating 24VDC Electric Motor and Gear Pump Assembly 24 STAB UNSTAB valve 24V DC UP UPFAST U
5. l Remove load from platform 2 Raise platform as high necessary to engage maintenance lock 3 Maintenance lock 15 located at the rear of the unit between the inside beam assemblies With machine raised part way lift maintenance locks and lower machine so that pivot pins are resting on maintenance lock Figure 3 MAINTENANCE LOCK Figure 3 Positioning Maintenance Lock WARNING DO NOT SERVICE EXTENDED OR PARTIALLY EXTENDED MACHINE UNTIL THE ABOVE PROCEDURE 15 FOLLOWED Introduction INTRODUCTION 10 Introduction DESCRIPTION Motrec 4805 18 electrically driven hydraulically operated units The platform 15 raised and lowered by a scissors mechanism Motrec E 480SC platform is raised by a hydraulic cylinder which 18 controlled from the control console on the platform Emergency lowering and auxiliary lift controls located at the base of the machine 26 ft 7 92 20 ft 6 10 m Figure 4 Motrec E 4808C 211 Introduction SPECIFICTIONS Through our constant efforts to improve our products specifications may change without notice 4505 Mobile Lift The 4805 15 engineered for large industrial plants that require rapid response over long distance The E 480SC is ideal for warehouse airport and in plant uses The E 480SC 15 the only vehicle of its kind and includes e Descent alarm and flashing light 45 volt drive controls and accessories e 24 volt hydrau
6. 2469002 36 48 3669002 11111313 5 Gauge 24V 2469026 36V 3069038 48V 4869037 Horn 12V 246003 24V 246013 82 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 converter 10A 12 48V 3069019 DC DC Converter 25 12 48 3124000002 72 80 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 a Cab heater 12V 3103300001 36V 3669008 48V 4869020 gt 12V Dome light 3669006 12V Fan 3669013 84 Headlamp 12V 3111250002 V TT 4 av INA 47 1 A 3111300001 3111300002 Headlamp 12V Bulb 12V Red Pilot light 12V Bulb 12V 246212 246212B 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 8 LED bar display When the left red LED lights the batteries must be charged to avoid damage The LED display starts flash
7. FLEX HOXE WASHER BOLT REF 13 15 16 17 19 20 22 23 25 71 2182480001 2185280001 2192320002 2910000017 2910000018 2916280002 2916480001 2183240002 DESCRIPTION SHACKLE LINK FORD PLATE LEAF SPRINGS 5000 Ibs cap BOLT LONG BOLT SHORT U BOLT 1 2 NF X 3 1 4 I D U BOLT 1 2 NF X 4 I D BOLT 5 8 NC X 4 FLAT WASHER 12mm MACHINE SCREW 1 4 X 3 8 NYLON NUT 5 8 NC HEAV Y NUT 1 2 NF BUSHING ELECTRICAL DIAGRAM SERIES MAIN CIRCUIT DIAGRAMME ELECTRIQUE CIRCUIT PRINCIPAL SERIES Spare Parts NONDVOT SoHLnv 11 60 0002 10 NOISHSA SI MIS LINDNID NIVW 8 02 31435 L23rans WHTIBLK A ai 1411 A MOSSIOS 5 vax T 72 Spare Parts ELECTRICAL DIAGRAM CHARGER AND BATTERY DIAGRAMME ELECTRIQUE CHARGEUR BATTERIES OSA 0508 3 J3AOHddv f 10 20 9002 10 NOISH3A E 00 531435 23 LOIW LINE aD uL AM3LLVG OL HO 9 LOINNOO 73 Spare Parts ACCESSORIES NO DC DC CONVERTER ACCESSOIRES SANS CONVERTISSEUR DC DC SA WAVLTSETLETHE 20 20 ON 59 d NONSYS T HOHLNY 00 60 9002 10 NO
8. 14 Cover assy housing also serviced in assy group 4010 Gasket cover to housing use DBAZ 19562 8 Shim differential bearing adjustment 241 thick 243 thick 245 thick 241 thick 248 thick 251 thick 253 thick 255 thick 251 thick 259 thick 261 thick 2B3 thick 265 thick 287 thick 269 thick 211 thick 278 thick 275 thick 277 thick 279 thick 281 thick 283 thick 285 thick 287 thick 289 thick 281 thick 293 thick 205 thick 207 thick Gear kit differential side usa with axle 87200 7245 7200 1987 Consists of 2 2 4228 Washer 2 E7TW 4236 Gear U washer axle shaft retaining Pin differential pinion shaft lock 0 ring axle shaft Bolt housing cover self locking 5167 18 x 5 8 serviced in essy group 4010 Use with axle WEC A B 7200 724S 7300 760B 7621 Use with axle 87800 762 Stud housing cover 5 16 18 5118 18 x 1 1 2 1000 8180 serviced in amp ssy group 4010 1038 with axle 760 762 Cup driving pinion bearing front 488048 Cone and roller drive pinion front bearing 88048 65 PART NUMBER FORD NON LOCKING REAR AXLE SERVICE PARTS LIST 237 09 2 D9AZ D9AZ D9AZ D9AZ 712 2 2 DSAZ 0942 2 E7TZ C7AZ 2 7 DSAZ 502
9. ADJUSTING FRONT HUBS Tighten spindle nut to 30 ft lb to seat the bearing and back off the nut to the next slot Install a new cutter pin and the dust 35 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 and B identify battery polarity and disconnect batter
10. HAVE ALL WORN OR DAMAGED PARTS REPLACED 4 FASTEN ENTRY GATE CHAIN BAR 5 USE WORK PLATFORM ONLY ON HARD LEVEL SURFACES OWNERS USERS AND OPERATORS ARE RESPONSIBLE FOR INSPECTIONS AND MAINTENANCE OF THIS MACHINE AS REQUIRED BY ANSI SIA A92 6 1990 CSA 3 B354 2 OR 3 M82 AND THE OPERATING MAINTENANCE AND PARTS MANUAL A 108585 44800012P Located on right side in middle 27 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 OILLEAKS X pp REVERSE ALARM DEADMAN SWITCH X 111 STATIC STRAP min 2 contact with ground X TIRE PRESSURE pressure rating tire x T T CHECK FI
11. Never use the vehicle hazardous areas where there are inflammable materials explosive dust or fumes in the e Have your vehicle inspected regularly by trained personnel and cease operation if malfunction occurs Do not open battery compartment to prevent battery explosion acid splashing severe damage to eyes or skin e 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 Donot exceed the vehicle cargo load capacity and gross trailing weight capacity rated for flat hard even surface Different operating conditions such as loose terrain or ramps reduce vehicle capacity e Avoid loose unbalanced or top heavy loads to keep a good stability and prevent overturn Do not load cargo that can fall off the vehicle Do not carry cargo that 15 longer wider or higher than this vehicle e Always depress slowly the accelerator for smooth acceleration Avoid stunt driving or horseplay e Avoid sharp turns always slow down before turning to prevent vehicle overturn or trailer jack knife Vehicle is more sensitive to overturn and jack knife when traveling on inclines or when carrying a heavy load e Always drive straight up and down the face of an incline never across the face
12. his Supervisor can clarify the misunderstanding through written correspondence or phone call to MOTREC inc 200 Indusrial Boul South Bromptonville Quebec Canada JOB 1HO Phone 819 846 2010 ext 226 Fax 819 846 3050 E mail info motrec ca Web site www motrec com SAFETY FEATURES l Platform won t move up if stabilizers are not fully extended Stabilizers won t disengage if platform is not fully down Vehicle won t travel if stabilizers are not fully retracted 2 Emergency Stop The emergency stop is located on the control console Depress red knob as indicated and all functions of machine will be de energized Pull the knob to reactivate circuits Figure 1 3 Emergency Down The emergency down control is located on the left side Pull handle to allow platform to descend back to the stowed position Figure 2 Emerzency stop huttons LIP SLOW DOWN STOP FAST Mechanical pull down handle Figure 1 Control Console Emergency Stop Figure 2 Emergency Down Handle Safety MAINTENACE LOCK warnine MAINTENANCE LOCK MUST BE INSTALLED WHEN MAINTAINING OR SERVICING MACHINE WITH PLATFORM FULLY OR PARTIALLY EXTENDED Working through beams on scissors lifting device creates a hazardous situation which could cause death or personal injury Whenever possible perform maintenance tnrough floorboards with the platform fullly lowered or from the outside of the base FOLLOW MAINTENANCE LOCK PROCEDURE
13. 3 8 NC NUT 5 16 NC Spare Parts MOTOR AND DRIVE AA ra NE NE COMMON PARTS REF DESCRIPTION PART Z RE DESCRIPTION PART Z 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 WASHER 484013 7 PIVOT 2452002 19 HEADBAND 484015 EE HEADBAND KIT 91 107 SPECIFIC REF DESCRIPTION A89 B98 00 DOOSEPEX DC3SEPEX DANA DRIVE MOTOR ASS 484000 204050 2950002 2450003 3112210001 3122230001 13 BRUSH SPRING 484010 484010 2450006 2450006 2450006 2450006 14 BRUSH PLATE 484011 484011 2450007 2450007 2450007 2450007 16 LEAD ASSY 484017 484017 N A N A N A N A 17 BRUSH 484009 484009 N A N A N A N A 18 LEAD AND BRUSH ASSY N A N A 2450008 2450008 3112210004 2450008 70 Spare Parts REAR SUSPENSION AND BRAKE REF PART NO 2120236001 481431 481430 2121000005 2121000006 2122236001 2122300001 2122300002 2128000002 2128000002 2129000001 2134000001 2139000002 2139000003 DESCRIPTION DISC RIGHT CALIPER LEFT CALIPER BUSHING LONG BUSHING SHORT MOUNTING PLATE CALIPER LEFT CALIPER SUPPORT RIGHT CALIPER SUPPORT PADS PADS CLIPS
14. ELEVATEUR CISEAUX DIAGRAMME ELECTRIQUE YOSSIIS HIHIHI XS0 L 531495 QSULOW 15 WHT BLS s Je 423rans BLK 10AW EEE NOI LV LS 1OH INOO er Spare Parts PARTS LIST DESIGNATION A4 SERIES SPEED CONTROL 350A 1205 5301 1 amp HORN B3 amp B3 A REVERSE amp DOWN ALARM 2 TAIL BRAKE LIGHT AMBER FRONT LIGHT FLA B C D E F F4 A B DIODE 367012 BATTERY PG BATTERY CHARGER N p M3 SERIES MOTOR 1 M4 WIPERMOTOR 1 2 MICROSWICH l gt 2 POTENTIOMETER 6000 l 2 2 PLASTICGEAR 60 1 X SPRING 2462008 1 81 00000000 486901IDP NO CONTACT 15 __ DPDTKEYSWITCHBASE I LIGHTSWITCH PUSHPULL 46002 512 BRAKE LIGHT SWITCH 246207 1 HYDRAULICBRAKELIGHT SWITCH 66904 1 513 FLASHERSWICH 5 O XI 7 HOURMETERCONNECTOR 11 X4 SPEED CONTROL CONNECTOR X5 ________ BATTERY CHARGERCONNECTOR __ WU Y17 DOWN VALVE SOLENOID 4874003 1 BUSSBARS 2469003 1 Consult Motrec Illustrated parts 78 Spare Parts CONFIGURATIONS 48 CONFIGURATIONS DES BATTERIES 48 e400 wm 500 Spp HHH 84 41 12V Accessories Ground 48V E 660
15. Reverse Wiring The forward reverse wiring schemes described here all assume the power wiring shown by the heavy lines in Figure 8 Some vehicles especially those previously using older resistor type controllers may reverse the motor armature rather than the field winding Be careful if you replacing this type of controller When using the Curtis PMC controller it is essential that the field be reversed and that the armature be connected directly to the 5 B and 2 terminals because the plug diode inside is connected to these terminals Curtis 1204 1205 1209 1221 Manual 54 13 MAINTENANCE amp ADJUSTMENT MAINTENANGE amp ADJUSTMENT Curtis PMC 1204X 1205X 1209 1221 controllers and potboxes require only minimal maintenance if properly installed NOTE The controllers are sealed and thus are not field serviceable CONTROLLER Maintenance It is recommended that the following two steps be performed occasionally First remove power by disconnecting the battery and discharge the capacitors in the controller with a light bulb or a 2 10 25 W resistor connected for a few seconds across B Follow good safety practices get the vehicle drive wheels off the ground wear safety glasses and use insulated tools see page 2 1 Make sure the electrical connections to the controller and to the motor contactors etc are tight When checking the controller bus bar connec tions for tightne
16. switch or coil Replace KEY switch Replace UP switch REPAIR PROCEDURE l NO LIFT MOTION pump not operating POSSIBLE CAUSES l 2 dd Hydraulic fluid level low Pump cavitations caused by improper fluid for temperature conditions Defective up valve or coil Defective down valve or coll Electrical circuit defective Loose intake hose or filter Defective high speed valve or solenoid Refer to electrical schematic 2 Replace brushes and spring 4 Replace pump relay coil or switch Replace contactor REPAIR PROCEDURE 18 2 42 SN Add fluid see Maintenance section Drain reservoir and bleed system Use only recommended type fluids see Maintenance section Replace up valve coll Replace down valve or coll Refer to electrical schematic Tighten Replace high speed valve or solenoid Maintenance ASCENT SPEED SLOW OR ERRATIC POSSIBLE CAUSES 1 Weak battery 2 Loose connections in electrical circuitry 3 Momentary short in wiring 4 Bent structural members Restriction in hydraulic hose Defective or Jammed seals in hydraulic lift cylinder Worn brushes valves 5 6 7 Gear or gear cavity worn or damaged 9 9 Defective valves 10 Defective high speed valve coil 11 Loose intake hose or oil filter 12 Defective down valve in manifold or in cylinder 13 Defective emergency down valve DESCENT SPEED SLOW POSSIBLE CAUSES 1 Flo
17. wheels off the ground secure with jack stands of adequate capacity disconnect charger Always wear safety glasses Batteries emit highly explosive gases that can be ignited by a spark Before disconnecting a high current terminal turn off all switches disconnect battery charger disconnect batteries Keep clear from moving parts such as tires sheaves and motor PMC SELF DIAGNOSTIC If your PMC comes with a status led use the flashing code to help troubleshooting BATTERY VOLTAGE Make sure batteries are securely connected Measure voltage between and terminals We will call this value B or full battery voltage ACCESSORIES NOT WORKING Check the fuses on the batteries and the DC DC converter Check voltage across and terminals on the battery gage if not B check wiring Turn the key switch ON check voltage between output terminal on the key switch and the terminal on the battery gage 1 not B replace the key switch Check voltage across DC DC converter output terminals 1f not 12 Volt replace the converter Depress the accessory switch check voltage across accessory terminals If not 12 Volt replace the switch If 12 Volt replace the accessory FORWARD ONLY On a SEPEX motor control check the reverse signal input on the controller On a series wound motor control a bad reverse contactor is the most probable cause of the problem Switch to reverse and check voltage on the reverse cont
18. 0001 22 2921000001 23 2127000006 24 2127000001 25 2191240002 ma 67 DESCRIPTION Spring Extention Yoke Cotter pin 3 32 x I Flat washer 5 16 Clevis pin 5 16 x 1 1 2 Handbrake lever Handbrake cable Clip Cable stop Handbrake band side cable Handbrake band Spring compression QTY N Spare Parts FRONT ASSEMBLY 68 Spare Parts REF 32 33 34 35 36 37 38 40 2100300002 2100300001 2100300003 2103250001 2103300001 2103300002 2104300004 2117250001 2120236001 481431 481430 2121000005 2121000006 2122300001 2122300002 2128280001 2128280001 2129000001 2134000001 2139000001 2139000002 2139000003 2180240001 2182320001 2185320001 2185488001 2192280001 2200300002 2200300003 2201320001 2201320008 2201360001 2201320009 2201360002 2205250001 2206300003 2206320001 2207000001 2207000002 2207300006 2207320001 2207320009 2206240001 2206240002 DESCRIPTION BUSHING BUSHING WITH OIL SEAL BUSHING THRUST BEARING TAPER BEAING TAPER BEAING OIL SEAL GEAR DISC RIGHT CALIPER LEFT CALIPER BUSHING LONG BUSHING SHORT LEFT CALIPER SUPPORT RIGHT CALIPER SUPPORT PADS PADS CLIP FLEX HOXE CALIPER PROTECTOR WASHER BOLT SHOCK ABSORBER SHACKLE LINK PLATE PLATE LEAF SPRINGS TUBE SH
19. 0012 Striped marking tape 4 4800012W Extending Platform capacity and security warning labels located on rear end 500 LBS MAX 4800012N DANGER TIP OVER HAZARDS DO NOT DRIVE NEAR DROP OFFS HOLES OPEN ELEVATOR SHAFTS AND LOADING DOCKS DO NOT RAISE PLATFORM ON UNEVEN OR SOFT SURFACES 3 DO NOT DRIVE ONTO UNEVEN OR SOFT SURFACES WHEN ELEVATED DO NOT RAISE PLATFORM ON SLOPE OR DRIVE 10 ONTO SLOPE WHEN ELEVATED Kul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
20. 036 2555487008 2555487013 2569487013 2569487015 2569487016 2569487018 2551487001 2551487008 2809487001 2553487001 2553487040 2553487030 3213 56 2553487052 2569487006 2569487060 2569487061 2107000032 2819487001 2554487001 2554487006 2554487031 2554487012 2554487030 2554487012 2554487021 2554487022 2569487067 2365000021 2569487054 2569487057 4800012 DESCRIPTION FRONT BUMPER BUCKET SEAT ON SLIDE ADJUSTETERS LEFT HANDLE RIGHT HANDLE WHEEL 18 O D LUG SOFT TOP CAB AND DOOR ROLL OUT TRAY SPRING LOCK PIN REAR LADDER RIGHT COVER LEFT COVER COVER WING REAR MOTOR COVER FRONT MOTOR COVER COMPARTMENT HYDRAULIC COVER STABILIZER FRAME STABILIZER LEG INSULATOR STABILIZER PLATFORM PLATFORM UPPER PART PLATFORM LOWER PART INSULATOR PLATFORM DECK EXTENTION DECK ROLLER SUPPORT ROLLER SUPPORT LEFT ROLLER SUPPORT RIGHT TRACK ROLLER ANCHORAGE HOOK FRONT GUARD RIGHT GUARD RIGHT GUARD LEFT GUARD LEFT GUARD RIGHT GUARD EXTENTION LEFT GUARD EXTENTION DOOR GUARD DOOR LOCK DOOR HINGE DASH SUPPORT DASH PLATE DECALS KIT INSULATED PLATFORM FLIP OUTSIDE OPTION CHANGE SIDE WHEN FLIP OUTSIDE OPTION 60 Spare Parts DOWN VALVE ASSEMBY LEFT SIDE 00082017 7 HO LIAS FUNSSTUd 800000ccr 98000002779 ONILLIA MOdTA LAN 8 DNLLLIA COOLSHOCTIE Arc 109 002870 YOLOATIOO 20 Id 10028704
21. 17 HATVA NM OG 1 00000 LAN 8 ONILLIA MO TA St 9700000 6T JN79 UL LAN NYI L800000CCH 00L8T01 Lt 8 DN Td dSVH HATVA 61 Spare Parts DOWN VALVE ASSEMBLY RIGHT SIDE 6701876955 000001 C6C NAOG 1104 dOLS LI F0L8T69SC 1 44118 TINd 00000061 C ONI IdS LANNIOT NOTAN 91 5 1 LANAOO T NOTAN v 91 970 87095 NMOG 11114 INF ILAN 5 X INTI LTO 62 Spare Parts REF PART NO 1 2360320012 2382320009 2 2360320014 2360320015 2360320024 2360320025 3 2803000003 2366320015 4 2365000001 2365000002 5 2367320002 2367320001 2367320008 2367320007 DESCRIPTION STEEL CAB SEATBACK CAB RIGHT DOOR LEFT DOOR RIGHT DOOR REAR PASSENGERS LEFT DOOR REAR PASSENGERS PADDLE LATCH DOOR LATCH RIGHT HINGES KIT LEFT HINGES KIT RIGHT DOOR GLASS LEFT DOOR GLASS CAB RIGHT DOOR GLASS REAR PASS LEFT DOOR GLASS REAR PASS 4 or 6 passengers option 63 PART NO 2801000002 280200000 1 2601000001 2399000014 3113000001 2600000002 2600000001 2366320001 2366320002 2366320003 2367300001 2367300002 DESCRIPTION REAR VIEW MIRROR TRIM DOOR SIDE MIRROR SIDE MIRROR BRACKET WIPER MOTOR WIPER ARM DOOR HANDLE DOOR HANDLE BAR DOOR LEVER REAR GLASS WINDSHIELD Spare Parts FORD F 150 DIFF
22. 56 9 regulations for vehicle maintenance Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect carriers vehicles tractors and batteries Before any maintenance work park the vehicle on flat level surface turn off all switches remove key lift wheels off the ground and secure with jack stands of adequate capacity Don t connect charger Keep clear from moving parts such as tires sheaves and motor Follow the maintenance instructions applicable to the type of repair maintenance or service Always wear a face shield and gloves when working around batteries Before opening the battery compartment disconnect the charger turn off all switches and remove the key Batteries emit highly explosive gases which greatly increase when charging do not disturb connections or produce sparks around batteries to avoid a battery explosion and acid splashing Battery acid causes severe damage to eyes or skin Flush contaminated area immediately with water Use insulated tools to avoid sparks that can cause battery explosion and acid splashing Use two counteracting tools double wrench technique when disconnecting or tightening terminals on the battery and the speed controller to avoid cracking the terminal or battery post welds Before cleaning or replacing a battery charger speed controller contactor relay diode or any other component in the power circuit always disconnect the charger turn off all
23. AFT AXLE BEAM LEFT SPINDLE LEFT SPINDLE BRAKES RIGHT SPINDLE RIGHR SPINDLE BRAKES KING PIN STEERING SUPPORT BOLT PATTERN 2 3 8 STEERING SUPPORT BOLT PATTERN 2 1 4 ROD END LEFT HAND ROD END RIGHT HAND REAR TIE ROD FRONT TIE ROD ARM STEERING WHEEL COVER Front axle with hydraulic disc brakes Front axle with shock absorber REF 41 42 43 44 45 46 47 48 50 51 52 53 54 55 56 57 58 60 6155 63 64 65 66 67 68 70 71 72 73 74 75 76 77 78 79 80 81 69 2219250001 2224300002 2229300001 2229300002 2229300003 2910000005 2910000006 2910000017 2910000018 2910000019 2910000020 2910000021 2910000022 2910000023 2910000024 2910300001 2910300002 2914364001 2916000001 2930000012 DESCRIPTION SPACER HUB DUST CAP OIL SEAL SPINDLE WASHER NUT LEFT HAND NUT RIGHT HAND BOLT LONG BOLT SHORT WHEEL NUT LOCK WASHER 7 8 JAM NUT 7 8 NF JAM NUT 3 4 NF SPRING PIN 14 X I 3 4 SET SCREW 5 16 NC CASTELLATED NUT 3 4 NF CASTELLATED NUT 1 UNEF BUSHING U BOLT GREASE FITTING BOLT 3 8 NC X 11 BOLT 5 8 NC X 4 BOLT 5 16 NC X I 1 4 BOLT 5 16 NC X I BOLT 7 16 NC X 2 CARRIAGE BOLT 1 4 NC X 3 4 FLAT WASHER 1 4 FLAT WASHER 12mm FLAT WASHER 7 16 COTTER PIN 3 16 X 2 COTTER PIN 7 64 X 2 MACHINE SCREW 1 4 X 3 8 NYLON NUT 5 8 NC LOCK WASHER 1 4 LOCK WASHER 5 16 LOCK WASHER 3 LOCK WASHER 7 16 HEAV Y NUT 1 2 NF NUT 1 4 NC NUT
24. DISCHARGE INDICATOR HOBBS ADDENDUM CURTIS FOOT PEDAL A WARNING DO NOT perform preliminary installations operate service replace adjust or maintain equipment on this machine until you have thoroughly read and understood the Safety section of this manual and have read and understood all the sections of this manual that apply to the job you are doing on this machine Failure to read all warnings posted on this machine and written In this manuel could cause death serious injury or property damage 61 63 64 67 68 70 71 12 73 74 75 76 77 79 82 83 85 86 87 Safety SAFETY Safety SAFETY WARNINGS FOR OPERATORS e FAILURE OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY e 15 the responsibility of the owner of this vehicle to train operators to ensure that they understand the operating characteristics of this vehicle including training in vehicle stability and obey the following safety rules and guidelines Owner shall comply with 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 qualified operator e 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 buildings e electrical system of this vehicle will make sparks which can ignite inflammable materials
25. E7UZ 4067 4067 AG 4067 4067 4067 4067 AL 4200 4204 4204 4211 4215 4216 4221 4222 4228 4228 4230 4230 4628 4630 A 4662 4663 4670 4676 4851 4851 389546 5100 170 6 2 4859 4859 DESGRIPTION Shim differentia bearing adjustment Cont d 299 thick 301 thick 303 thick 305 thick 307 thick Differential assy refer to group in Section 40 Case assy differential Use with axle 87206 7245 7200 1987 Shaft differential pinion kit use with axle 87200 7245 7300 1987 Consists of 1 E7TW 4211 Shaft 1 0887 4241 4 Pin Pinion kit use with axle 87200 7245 730D 1987 Consists of 2 E7TW 4215 Pinion 2 2 4230 Bolt differentlal case self locking 7116 20 x 3 4 Cone and roller differential bearing LMB03049 Cup differential bearing LM603012 Washer differential side gear thrust also serviced in kit group 4236 Use with axle 7200 7245 7300 1987 Washer differential pinion thrust also serviced in kit group 4215 Use with axle 7200 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 10 x 15 32 long collapsible also serviced in kit group 4209 Shim pinion bearing serviced only in kit aroup 4209 Slinger pinion shaft o
26. ENTRY DO NOT DRIVE NEAR DROP OFFS HOLES OPEN ELEVATOR SHAFTS AND LOADING DOCKS SE DO NOT RAISE PLATFORM ON GATE CHAIN BAR IN PLACE 3 3 DO NOT USE IF WORK PLATFORM 15 NOT WORKING DO NOT DRIVE UNEVEN PROPERLY OR IF ANY PART IS DAMAGED OR WORN is E i 1 SOFT SURFACES WHEN ELEVATED USE NEAR MOVING VEHICLES OR CRANES 5 DO NOT STAND OR SIT ON GUARDRAILS 6 DO NOT USE UNDER THE INFLUENCE OF ALCOHOL OR DRUGS 7 DO NOT OVERRIDE SAFETY DEVICES 8 DO NOT LEAVE MACHINE UNATTENDED WITH KEY IN KEY SWITCH 9 DO NOT RAISE PLATFORM WHILE MACHINE IS ON A NOT SUE DRIES ccs er ocn TRUCK FORK LIFT OR OTHER DEVICE OR VEHICLE 10 DO NOT USE LADDER SCAFFOLDING OR OTHER _ SLOPE WHEN ELEVATED DEVICES TO INCREASE SIZE OR WORKING HEIGHT OF PLATFORM 11 DO NOT USE WITH IMPROPERLY INFLATED TIRES 12 DO NOT USE WITH DAMAGED WHEELS OR TIRES Bn ka GLA 13 DO NOT USE WITH TIRES OR TIRE FILLS THAT ARE NOT PER MANUFACTURER S SPECIFICATIONS REFER TO MAINTENANCE MANUAL Safety PERSONNEL QUALIFICATIONS Operation of 4805 shall be restricted to certified personnel as required by OSHA Maintenance of E 480SC shall be restricted to qualified trained personnel as required by Before operation or maintenance personnel shall read and thoroughly understand this manual If a proposed operator or maintenance man fails to understand any segment of this manual
27. ERENTIAL 242063 BREATHER 242054 BOLT fu 3620007 C 22071 HOUSING BEARING SEAL RING KIT 3620020 55753 S CONE amp CUP 84 4216 385696 5 4230 LOCKTITE RTV Cw 3620020 WW o 373098 5 CONE amp DE 7 2 d Re I 373820 5 155 4614 3620023 275 O D OIL SEAL 3620024 3 0 O D OIL SEAL 3621001 PULLEY W80 8 O D LOCKTITE RTV 3621002 PULLEY W30 9 3620011 GEAR KIT 3620022 CONE amp CUP 3620022 amp CUP BREATHER 2320004 MOUNTING PLATE 242063 EW LT 1 2 MF X 3 NEW 2320006 SPACER 4420003 RETAINING RING HOUSING 4420005 RETAINER Ps 242054 BOLT 64 Spare Parts QTY am 10 PART NUMBER 373098 5100 42 8 2 D9AZ D9AZ D9AZ 09 2 09 2 09 2 D9AZ D9AZ D9AZ D9AZ D9AZ D9AZ 0942 D9AZ D9AZ D9AZ D9AZ 9 2 D9AZ D9AZ D9AZ D8AZ D9AZ D9AZ D9AZ D8AZ 09 2 0942 D9AZ E7TZ 7 2 0887 E6TZ 6 2 E5TZ 4033 4036 4067 4067 4067 8 4067 0 4067 D 4067 4067 4067 6 4067 4067 4 4067 4067 L 4067 M 4067 N 4067 P 4067 R 4067 5 4067 T 4067 1 4067 V 4067 W 4067 4067 4067 2 4087 4067 4067 4067 AD 4067 4067 AF 4236 4N237 A 4241 4 332 4346 4346 4346 4246 4616 4621 DESCRIPTION Plug housing 1 2
28. ISHBA 2Q 20 E NMLISLILETIHE DIV 4oarens BLK RED GRN BLK 18 18 5940552296 uo APZ JO AZ 1 SI eAnejal ayy USYE jou SI uondo 30 90 sod eAgisod aapea 1500 SJE PSLUISJUI JE si sauossaooy OS NHS NHD 8 i 2 e ves Y Y i LHM 2 1 i name 1 1 hn E 1 x a 73A E i 215 4 13A i ETN EN zum u usa au AA OE TE 74 Spare Parts ACCESSORIES DC DC CONVERTER ACCESSOIRES CONVERTISSEUR DC DC _ OSANMIISVLTINE 20 00 DOV kon NONDYST HOHLNYV 12 075006 HILYIANDD 20 20 S3IHOSS322OV WNMLISLILZIHZ 227 334 LOIN HIE LING 75 Spare Parts OPTIONS OSA SYHSHSV 14 SNOLLdO ONIMVHO NONOVO f HOHLNVY NOISH3A 5 5 14 5 4 423 8 5 QSULOW WHT ata x 5 z 215 LM 76 Spare Parts SCISSOR LIFT ELECTRICAL CIRCUIT
29. JUST ACCELERATION RATE ADJUST CW higher plug current CW faster acceleration Use the following adjustment procedure The keyswitch should be off during adjustment 1 Remove the socket head screw 1 8 Allen for the adjustment you want to make 2 Adjust the internal potentiometer using a small insulated screwdriver available from Curtis 3 Replace the socket head screw and nylon seal washer To prevent stripping do not over tighten POTBOX Maintenance Potbox maintenance 15 similar to controller maintenance inspect for integrity of connections and mounting and clean with a moist rag as required Adjustment Curtis PMC potboxes are factory set and rarely require user attention To test and adjust connect an ohmmeter to the potbox wires and use this procedure 1 With the spring holding the lever arm against the return stop the resistance should be less than 50 ohms Slowly move the lever If the resistance abruptly starts to increase when the lever is mm 1 8 from the stop 1 5 mm 1 16 for potboxes without the microswitch no adjustment is needed Curtis 1204 1205 1209 1221 Manual 56 23 MAINTENANCE amp ADJUSTMENT 2 If adjustment is required loosen the screw holding the lever on the pot shaft Use a screwdriver to rotate the pot shaft slightly with respect to the lever Recheck the point at which the resistance starts to increase and continue making adjustments until the inc
30. LL BATTERIES add distilled water to cover plates Fill to recommended level after batteries have X been fully charged WARNING DECALS amp MARKINGS 1 X EE Rated CABLE PROTECTORS SEALED MOTOR SEALED CONTROL BOX MASTER CYLINDER FLUID X 2 50 mm maximum travel STEERING FOR PAY X PARKING BRAKE LEVER requires 10 Ibs 5 kg force to apply BELTS AND PULLEYS 10 Ibs 5kg force for 1 8 3mm deflexion pulleys alignment see procedure CLEAN TIGHTEN WIRE TERMINALS 11 WASH BATTERY WITH WATER 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 for wear amp play BRAKE LININGS FOR WEAR 1 16 1 5 mm minimum lining thickness LUBRICATE brake pedal pivots steering column ball joints and kingpins OIL SAE 30 LEVEL IN DIFFERENTIAL Before adding oil check oil seals for leaks FRONT WHEEL BEARINGS PLAY OX TIGHTEN NUTS BOLTS electric terminals drive TNT steering brakes suspension body REPLACE DIFFERENTIAL OIL SAE30 CLEAN AND RE PACK FRONTHUBS SERVICE DIFFERENTIAL replace the three oil seals wheel bearings oil SAE 30 28 Maintenance SCISSOR PERIODIC CHECKLIST
31. MOTREC 4805 AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1038854 amp UP Printed in Canada One Year Limited Warranty Effective April 25 2005 Inc hereby warrants to the Original Retail Purchaser Owner that any of its vehicles shall be free from any defect in materials for a period of 90 DAYS while the possession of such Original Retail Purchaser This warranty I5 NOT TRANSFERABLE to any subsequent Buyer The warranty period is extended to one year or one thousand 1 000 hours which ever first occurs on the electric motor differential parts that bathe in oil and the electronic speed controller MOTREC makes no warranty or representation with respect to the internal combustion engine tires and batteries since their respective manufacturers cover such parts Accessories light gage horn etc electrical contacts switch solenoid contactor relay diodes amp fuses belts amp pulleys filters amp spark plugs lubricants brake linings amp shoes brake drums amp discs seals seats trim and other items subject to wear are not included in this warranty nor is any item that in MOTREC sole opinion shows evidence of neglect misuse abuse collision or alteration This warranty shall not apply to normal maintenance requirements as described in the User Manual and to damages during shipment The latter is the carrier s responsibility N
32. O PLUG 149735 CORDSET DC WITH SILICONE PLUG 80205 CORDSET DC WITH LESTER PLUG 086075 CORDSET DC WITH 50 AMP ANDERSON PLUG 105365 CORDSET DC WITH 50 AMP EZ GO PLUG 082245 CORDSET DC WITH 175 AMP ANDERSON PLUG 083135 PLUG 55 DC 50 AMP ANDERSON PLUG 029575 PLUG ASSY DC 175 AMP ANDERSON PLUG 82 Spare Parts Strobelight polemount Amber 12 80V 3116000001 Red 12 80V 2469001 Blue 12 80V 3690008 Strobelight cab mount Amber 12 48 3116250001 Red 12 48V 3069026 Blue 12 48V 3069014 Amber 72 80V 3116720001 Red 72 80V 3116720002 Blue 72 80V 3116720003 Amber turn lamp 12V 3069020 Bulb 12V 3069021 Red Tail Brake light Grommet 3269001 Plug 246012A 12V 2469021 24V 2469022 Red Tail Brake light 2 386002 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
33. PSLOW valve 2 speeds optional Pump inlet hose Flow control Down Speed Flow control Up slow Speed 2 speeds optional Relief valve Set to 2000psi T Q T m Hydraulic Pump Motor Servicing Common maintenance on DC motors 15 brush replacement It Is recommended that brushes be checked and replaced if necessary along with commutator inspection approximately every six months The time interval will greatly vary depending on how the machine is being used and the condition of the battery it is to your advantage to keep the batteries fully charged and in top condition to eliminate service problems in general and to extend the life of the motor and brushes See Battery Servicing Platform Speed Valve Adjustment 1 Unscrew setscrew then turn flow control valve See item F amp G figure 20 knob til you desired speed is reached 2 Tighten setscrew 46 Maintenance Hydraulic Lift Cylinder Replacement WARNING MAINTENANCE LOCK MUST BE INSTALLED when maintaining or servicing machine with platform fully or partially extanded Working through beams on scissors lifting device creates hazardous situation which could cause death or personal injury FOLLOW MAINTENANCE LOCK PROCEDURE ON PAGE 3 OF THIS MANUAL Raise platform Engage maintenance lock See Maintenance lock Lower platform until beam assemblies touch maintenance lock Wrap a self tightening strap around center of the cylin
34. RTANT IMPORTANT IMPORTANT Real and follow safety and operating instructions TABLE OF CONTENTS SAFETY SAFETY WARNINGS FOR OPERATORS USE OF NOTES CAUTIONS AND WARNINGS GENERAL OPERATING RULES SAFETY AND LIMITATIONS PERSONNEL QUALIFICATIONS SAFETY FEATURES MAINTENACE LOCK INTRODUCTION DESCRIPTION SPECIFICTIONS OPERATION PRELIMINARY INSTALLATIONS SCISSOR LIFT OPERATION PROCEDURE TO MOVE VEHICLE HYDRAULIC OIL FILL UP PROCEDURE OPERATING INSTRUCTIONS MAINTENANCE SAFETY WARNINGS FOR SERVICE TECHNICIANS DECALS AND LABELS PERIODIC MAINTENANCE CHECKLIST SCISSOR PERIODIC MAINTENANCE CHECKLIST SCISSOR LIFT INSPECTION AND LUBRICATION WEEKLY LOG INSPECTION AND LUBRICATION ACCELERATOR BELT INSTALLATION AND TENSIONING HYDRAULIC BRAKES FRONT AXLE AND STEERING BATTERY MAINTENANCE BATTERY CHARGER ELECTRICAL TROUBLESHOOTING SCISSOR TROUBLESHOOTING HYDRAULIC SYSTEM CURTIS PMC MOTOR CONTROLLER OVERVIEW WIRING STANDARD CONFIGURATION MAINTENANCE AND ADJUSTMENT SPARE PARTS BODY Table of contents DOWN VALVE ASSEMBY CAB FORD F 150 DIFFERENTIAL BRAKE CONTROLS FRONT ASSEMBLY MOTOR AND DRIVE REAR SUSPENSION AND BRAKE ELECTRICAL DIAGRAM SERIES MAIN CIRCUIT ELECTRICAL DIAGRAM CHARGER AND BATTERY ACCESSORIES NO DC DC CONVERTER ACCESSORIES DC DC CONVERTER OPTIONS SCISSOR LIFT ELECTRICAL CIRCUIT BATTERY CONFIGURATIONS 48V BUILT IN PORTABLE 25A CHARGER MOTREC ILLUSTRATED ACCESSORIES BATTERY
35. USE WITH IMPROPERLY INFLATED TIRES DO NOT USE WITH DAMAGED WHEELS OR TIRES DO NOT USE WITH TIRES TIRE FILLS THAT ARE NOT PER MANUFACTURER S SPECIFICATIONS REFER TO MAINTENANCE MANUAL 4800012 24 Maintenance Security warning label on platform control box ELECTROCUTION HAZARD THIS MACHINE IS NOT INSULATED MAINTAIN SAFE CLEARANCES FROM ELECTRICAL POWER LINES AND APPARATUS YOU MUST ALLOW FOR PLATFORM SWAY ROCK OR SAG THIS AERIAL DEVICE DOES NOT PROVIDE PROTECTION FROM CONTACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR DEATH OR SERIOUS INJURY WILL RESULT FROM SUCH CONTACT OR INADEQUATE CLEARANCE SJ 102661 44800012E located on the top of box UP DOWN STOP FAST 44800012Q 44800012U 4800012Z Optional 2 speed up Maintenance Lock security warning label Located at the rear end 4800012G Lower control station labels STAB UP UNSTAB DOWN 4800012R 4800012T 25 Maintenance Battery security warning labels A DANGER Tip over hazard Failure to replace batteries with proper weight batteries will cause death or serious injury Batteries are used as counterweight and critical to machine stability REPLACEMENT BATTERY MUST WEIGH Each battery mttstw loh MINIMUM OF 60 POUNDS 65 pounds 29 5 kg x FAILURE TO MEET MINIMUM WEIGHT x REQUIREMENT MAY CAUSE MACHINE INSTABILITY 43617 017 8520 44800012H Located on battery
36. are provided for the high current connec tions to the battery and motor Negative connection to battery Positive connection to battery and to motor armature Output to motor field Plug diode to motor armature The cables used for the battery and motor connections must be heavy enough to carry the high current required Rubber insulated welding cable is convenient to work with because of its flexibility Connections to the controller bus bars should be made with lugs suitable for the cable used fastened by M8 5 16 bolts and nuts When tightening the bolts two opposing wrenches should be used Failure to use the double wrench technique could cause undue strain to be placed on the internal connec tions and could also result in cracked seals around the bus bars WIRING TYPICAL INSTALLATION Curtis 1204 1205 1209 1221 controllers are designed to satisfy the requirements of material handling applications using series motors Figure 8 is a schematic diagram of the installation shown in Figure 7 Wired this way the vehicle will plug brake if the direction 16 changed with the vehicle moving and the throttle applied Reversing is accomplished via a forward reverse changeover contactor or two single pole double throw 2xSPDT contactors Coil suppres sion diodes should be used on the main and forward reverse contactors KSI Wiring The keyswitch input KSI circuit includes inputs from the keyswitch and from th
37. connector side DANGER Failure to obey the following battery and charger safety rules will cause death or serious injury Burn Hazards Explosion Hazards Electrocution Batteries contain acid sparks flames and Hazards Always wear protective lighted tobacco away from Connect charger to a clothing and eyewaear batterigs Batteries emit grounded AC 3 wire when working with axplosive gas electrical outlet only batteries Battery tray should be open Before each use inspect Avoid spilling during entire charging cycle for damaged cord cables contact with battery Do not contact battery and wires Replace BATTERIES PRODUCE acid Neutralize battery terminals or cable clamps damaged items before EXPLOSIVE GAS acid spills with baking with tools that may cause operating VERA E ED sparks Component Damage CHARGE BATTERIES IN n Avoid contact with hot Lifting Hazard Hazard WELL VENTILATED AREA 4 i live electric proper lifting techniques Do not use charger I 1 Do not expose and appropriate number of greater than 244 to charge DO NOT EXPOSE TO batteries or charger to people when lifting batteries batteries SPARKS OR FLAMES water and or rain 4800012K Located on top of battery tray connector side BATTERY DISCONNECT PULL 48 4800012J Located near the battery connector 26 Maintenance Lower Railing
38. der With a lifting device apply upward pressure Remove high pressure hose from lower end of cylinder Remove cylinder pin retainer plates on both sides of cylinder mounting top amp bottom Remove top cylinder pin and bottom cylinder pin Raise cylinder up and out of machine Replace cylinder and reassemble in reverse order Bleed air from system by raising and lowering platform 6 times Recheck fluid level in down position wi Lu 24225 UPPER TE 1227 _ CYLINDER __ PIN gt E et M s ES E d CYLINDER e RETAINER H JG PLATE MISS ka LOWER _ T CYLINDER he 0N 2228 CYLINDER RETAINER PLATE Figure 21 Removing Lift Cylinder Pins and Retainers Outer Beams and Inner Beam Assembly Replacement When replacing damaged or worn scissor lift beams care must be taken to assemble beams so that outer beam washer reinforcements face toward inner beam assemblies 47 Curtis Speed Controller CURTIS PMC MOTOR CONTROLLER 48 MANUAL CURTIS 1204 1205 and 1209 1221 MOTOR CONTROLLERS O 1999 CURTIS INSTRUMENTS ING DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 1204 1205X 1209 1221 Manual p n 98796 Rev D 1999 49 Fig 1 Curtis PMC 1205X full feature electronic motor controller Model
39. e section 3 Defective manual emergency down 2 Replace valve valve 3 Replace valve DRIVE FUNCTION INOPERATIVE motor not operating POSSIBLE CAUSES REPAIR PROCEDURE 1 Defective FORWARD REVERSE switch 1 Check continuity Replace switch 2 Defective electrical circuitry 2 Refer to electrical schematic 3 Defective motor contactor 3 Replace contactor DRIVE FUNCTION INOPERATIVE IN EITHER DIRECTION motor not operating POSSIBLE CAUSES REPAIR PROCEDURE 1 Defective FORWARD REVERSE switch 1 Replace switch 2 Defective drive PMC coll 2 Replace drive or coil 3 Defective electrical circuitry 3 Refer to electrical schematic 4 Low battery 4 Charge battery 5 Defective motor 5 Replace drive motor NO MOTION IN ONE DRIVE DIRECTION ONLY POSSIBLE CAUSES REPAIR PROCEDURE 1 Defective FORWARD REVERSE valve 1 Replace defective valve or solenoid or solenoid faulty 2 Defective electrical circuitry 2 Refer to electrical schematic 44 Maintenance HYDRAULIC SYSTEM Hydraulic System Bleeding The hydraulic system is self bleeding After the system has been drained such as during the replacement of a hydraulic system component actuate the platform full up and down for six cycles and recheck the reservoir fluid level between each cycle Fill as required Cil Filter Replacement The oil filter in the hydraulic system should be changed yearly Replace with filter part 44874007 only Figure 19
40. e terminal areas Dust Particles or acid contamination can create current leaks and cause malfunction Check F R switch Turn on the key switch and set to forward Check voltage between the forward terminal and the terminal on the battery gage check voltage between the reverse terminal and the terminal on the battery gage if both B replace the F R switch Check switches and wiring Disconnect control terminals on the PMC and check all control signals If 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
41. e various interlocks The controller KSI is used to turn the controller on and off KSI is turned on by connecting it to battery B Any positive voltage greater than about 8 volts will turn on the controller but usually the full vehicle battery voltage Is used In its simplest form KSI is operated by a keyswitch that turns the vehicle off and prevents unauthorized use The keyswitch should also turn off the main Curtis 1204 1205 1209 1221 Manual 53 12 WIRING L 5 j CONTEA KEYSWITCH INTERLOCKS TUN not used with SRO controllers gt uot POLARITY 4 PROTECTION POWER WIRING DIODE FUSE MAIN PRECHARGE RESISTOR 250 5 C N T 7 2 N A lt lt POTBOX gt F E r _ S1 52 L Z KSI F R cont out ee Ld Bypass cont output Emergency reverse E EWD input NN 3 REV input 1A BYPASS See Figure 10 for emergency reverse Fig 8 Basic wiring configuration Curtis PMC 1204X 1205X 1209 1221 controllers contactor and the forward reverse contactors This will act as safety feature by removing power from the motor control system when the keyswitch is off Interlocks seat switches battery charger interlocks etc should be wired in series so that they turn off the controller KSI and the contactors An SRO interlock a seat switch for example must be wired in order to implement the optional SRO feature Forward
42. eck that platform extension slides freely and gate swings freely NOTE To install extending platform refer to the extending platform illustration in this manual 3 Make sure carrying capacity and warning decals provided state correct capacity for your machine and are installed to platform as illustrated Figure 5 Platform Railings and Warning Decal 14 4 If not assembled before shipment connect cable to control console provided and install console on platform railing Pull emergency stop button if it has been depressed Figure 6 If wheels have not been installed install them Pull emergency stop button on lower control station if it has been depressed Figure 6 Check oil level in hydraulic reservoir see sight glass See next page fill up procedure Inspect machine for hydraulic oil leaks Do not use the machine until leaks are serviced o o SCISSOR LIFT OPERATION PROCEDURE 9 Turn key switch at lift position 10 Fully extend stabilizers using toggle switch at stab position at lower control station Make sure legs will stand on even surface 11 Move up platform using toggle switch at position at lower control station or using toggle switch position upper control station To stop platform movement release the toggle you have 2 speed option Lower station default is up fast while upper station default is upslow Simply press upslow switch and
43. ere damage to eyes or skin Flush the contaminated area immediately with water BATTERY CHARGER Park the vehicle in 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 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 KEYSWITCH LIGHTS Three positions with off at center Depress brake pedal and turn the key switch clockwise for F R position and turn headlight on Turn key switch clockwise to operate the platform Always turn off all switches set the F R selector to neutral set the parking brake and 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 and remove the key before leaving the vehicle ACCELERATOR PEDAL It is designed for right foot opera
44. es a hazard The driver is responsible for the control of the vehicle while driving and must always evaluate and care for all peculiar situations that he or she may meet while driving The driver assumes the inherent hazards related to this activity The vehicle is designed for off road use only MOTREC disclaims any liability for incidental or consequential damages to include but not be limited to personal injury or property damage arising from vehicle misuse lack of maintenance or any defect in the vehicle It is the responsibility of the Owner of the vehicle to make sure that the service technicians are properly trained as required by OSHA and ANSI B56 Service technicians shall read understand and follow instructions in the MOTREC manual before servicing the vehicle Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect the vehicle MOTREC prohibits and disclaims responsibility for any vehicle modification altering the weight distribution and stability increasing the speed or affecting the safety of the vehicle Such modifications can cause serious personal injury or property damage for which MOTREC disclaims any responsibility For Owners that are located outside North America the warranty period starts the date of shipment from the factory and the defective parts must be returned at the Owner s expense to MOTREC prior to warranty repair 20 04 2006 Table of contents IMPORTANT IMPO
45. fast button at the same time to get upfast function UPPER STATION LOWER CONIROL STATION UP SLOW DOWN STOP FAST Figure 6 Controls 12 SURE MAINTENANCE IS SECURELY POSITIONED ON ITS SUPPORT AND WON T DISTURB BEAN MOVEMENT 13 Use toggle switch at down position to move platform downward any station stop platform movement release the toggle 15 MOVE VEHICLE 14 To unlock stabilizers activate stab switch and pull unlock lever Keep pulling lever while activating unstab switch to retract stabilizers If lever 15 little bit hard to actuate simply press STAB switch for a while at lower control station then apply sufficient force to actuate UNLOCK main lever IFRGENCY Figure 7 Unlock main lever 15 When stabilizers are fully retracted sit down turn key switch at F R position to move vehicle set F R switch for direction NOTE Stabilizers must be fully extended to operate the platform or fully retract to move vehicle forward reverse If the platform is partly raised stabilizers cannot be activated HYDRAULIC OIL FILL UP PROCEDURE e Lower platform so that maintenance lock is resting on pivot pin WARNING Maintenance lock must be installed when maintaining or servicing machine with platform fully or partially extended Working through beams on scissors lifting device creates hazardous situation w
46. heck the continuity of the dc output cord ammeter diodes and all connections in the dc circuit Check diodes Check capacitor rapidely increasing resistance SINGLE CHARGER FUSE BLOWS Disconnect and check diodes BOTH FUSE LINKS BLOW Check the battery pack and battery connector polarity Disconnect and check diodes CHARGER OUTPUT IS LOW Disconnect and check diodes Can be caused by a transformer failure AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES Check the battery pack CHARGER DOES NOT TURN OFF Check specific gravity in each battery cell As much as 16 hours may be required to properly charge heavely discharged new or cold batteries Replace electronic control AC LINE FUSE OR CIRCUIT BREAKER BLOWS Check cordset Check ac line fuse rating Replace electronic control Can be caused by a transformer failure 38 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
47. hich could cause death or personal injury Follow maintenance lock procedure on page 3 of this manual e Remove filler cap and check fluid reservoir Fill to proper level using AWE32 hydraulic oil e Replace filler cap Raise platform slightly and retract maintenance lock e Inspect hydraulic system for leaks Check oil leakage at leg bottom hole A WARNING Never inspect hydraulic hoses with hands Escaping fluids under pressure can cause serious injury Use a piece of cardboard or other material to inspect for leaks Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury If any fluid is injected into your skin see doctor at once Injected fluid must be surgically removed by a doctor familiar with this type of injury or gangrene may result 16 OPERATING INSTRUCTIONS It is the responsibility of the owner of this vehicle to ensure that the operator understands the operating characteristics of this vehicle and obeys the safety instructions ANSI B56 Do not drive this vehicle unless you are qualified operator BEFORE USING VEHICLE Before turning on key switch set to neutral check for any visible damage check brake pedal BATTERIES Never open the battery compartment unless you have received proper training for battery maintenance Batteries emit explosive hydrogen gas that can be ignited by spark or loose terminal Battery acid causes sev
48. ich can build up in and around the batteries Follow the battery manufacturer s safety recommendations Wear safety glasses Curtis 1204X 1205X 1209 1221 Manual 51 2 WIRING WIRING CONNECTIONS Low Current Two 1 4 push on terminals are provided for the throttle inputs If your controller has voltage throttle input there will be only one throttle terminal 6 low power connector molded into the right side of the controller face provides the low power logic control connections KSI input forward reverse contactor output bypass contactor output optional emergency reverse optional and forward and reverse inputs Keyswitch input KSI Throttle inputs F R contactor output Bypass contactor output Emergency reverse input Forward input Reverse input Several manufacturers make mating connectors that fit this connector The part numbers listed are for the recommended 0 75 18 AWG vinyl insulated stranded wire MFR PART NUMBER DESCRIPTION AMP 640426 7 locking insulation displacement terminals wires at right angle to connector Methode 3300 107 218 locking insulation displacement terminals Molex 09 50 3071 locking crimp terminals Panduit CE156F18 7 locking insulation displacement terminals wires at right angle to connector Curtis PMC 1204X 1205X 1209 1221 Manual 52 11 WIRING CONNECTIONS High Current Four tin plated solid copper bus bars
49. il Seal assy drive pinion cil HESDW 4676 Flange assy universal joint axlo end 1330 size 1987 Locknut and washer assy flange to piaion 3 4 20 also serviced in kit group 4209 Deflector driving pinion oil 8881 Plastic From 1 86 1986 Spare Parts BEARING 1 0 BEARING 1 0 SPLINE BEARING 1 0 BEARING 1 0 02 SPLINE 28 31 28 31 28 31 28 31 31 28 31 31 28 31 28 28 31 26 Fl 23 88 4 1 374 26 2635001 16 88 HE 1 774 2835001 GM 1 774 6635001 lt 11 125 1 395 242052 14 125 HE 1 395 282052 1685 4 198 382052 GM 4 j 1 2420014 1415 4 A 2820004 GM 12 6 2820013 gt 2235007 3020004 17 12 5 1 374 26 3620005 26 26 27 27 24 24 24 24 66 Spare Parts REF N 1 ON ON A Q Lt 10 11 12 13 2910000015 2930000012 2131100002 2131360002 2131360012 2133280001 2132320001 2125000001 FF version BRAKE CONTROLS DESCRIPTION Nut 1 4 20UNC Yoke Lock washer 14 Lubrication fitting Rubber pad Lever Lever Push rod Master cylinder Nut 3 8 16UNF Pivot Boot included with 42125000001 Master cylinder Clevis pin 3 8 x 1 3 32 Cotter pin 3 32 x I REF PART NO 14 2190000003 15 2910000013 16 17 18 19 2139240002 20 2129000003 21 212900
50. ing Pivot Points 0 Ki 2 Oil Brake PivotPoints l 3 Gheck All Fasteners JIPPI MAINFRAME TT TE Ki Ki Gss controcsystem 0 jj jj 1 Ghack Terminals and Pugs 2 Check Cords p EN ne Check every 6 months TABLE 11 SCISSOR LIFT INSPECTION AND LUBRICATION WEEKL LOG 30 Maintenance INSPECTION AND LUBRICATION Structure Inspection 1 Check machine for bent structural members Beams main frame platform pivot pins etc Machines which have been overloaded could have bent members and fatigued pivot pins Replace all bent members and pins to insure safe operation machine 2 Check bushings in scissor beams for or cracked welds Replace beams if bushing welds are cracked or bushings elongated A WARNING All pivot areas of scissors and lift cylinder must be checked for wear A loud scraping noise means the bushings are damaged and need replacing Failure to do so will result in extensive damage to structural members and bushings which would create a hazardous condition and could result in injury or death to personnel Lubrication 1 The 4805 scissor lift contains several pivot pins or rollers that require lubrication Figure 9 2 Steering rod linkage pivot and joint also require lubrication Figure 9 Lubricate pivots 3 Maintenance ACCELERATOR GEAR Remove the cover Back
51. ing as a pre warning signal The lower voltage limit 1s adjustable via potentiometer on the rear B D J K 1 89 1 93 In order to activate new adjustment the unit has to be reset 2 35V cell reset voltage with battery remaining in vehicle 2 09V cell reset voltage after battery has been disconnected To maintain a good battery performance it is recommended to limit the discharging to 80 of the battery capacity The recommended setting for 6V batteries 1s F and the recommended setting for an industrial battery 15 K An internal relay can prevent overdischarging and damaging the batteries The relay can be wired to cut off the reverse direction or energize an N C relay and alarm Turning off and on the vehicle will override the protection for 30 sec The current status remaining operating hours before maintenance of the service down counter is indicated for a period of 5 seconds after the key switch 1s turned on When it 15 down to 0 the display flashes After the maintenance reset the counter depress the button on the rear The service counter 15 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 85 Addendum ADDENDUM 86 Addendum CURTIS FOOT PEDAL KEY SWITCH HOUR METER POTENTIOMETER
52. lash between gears must be reduced to minimum by sliding holder use locktite 262 to lock the three screws When the plastic gear is fully depressed 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 is released turn the adjusting screw shown on figure below to adjust the micro switch height POT Remove the terminals 2 and 3 on PMC to measure resistance signal When the micro switch 15 activated the signal must be less than 50 ohms When the front portion of the pedal is fully depressed the signal must be more than 4600 ohms To modify the resistance turn the adjusting screw to change the micro switch height see figure below Proceed with the same verifications after the accelerator cover 15 and then connect terminals 2 and 3 POTENTIOMETER AUXILIARY SWITCH IS WIRED N O WITH BLUE LEAD TO COM amp ORANGE LEAD N O CIRCUIT THE GREEN LEAD 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 ES ADJUSTING SCREW ACTUATOR PIN 32 Maintenance BELT INSTALLATION AND TENSIONING INSTALLATION Adjust the sprockets using a straight edge Slide
53. le At 20 state of charge specific gravity of 6V battery should be 1180 and 1220 for industrial battery CHARGING AREA Always charge battery well ventilated area set for and approved for charging Never leave charger connected for more than 20 hours FREQUENGY OF CHARGE When a battery is discharged to its 20 state of charge it 15 best to charge immediately Batteries require a low current equalization charge min 4 hours at least every week to equalize battery cells improve battery performance and life in number of cycles Never leave a charger connected for more than 20 hours STORAGE Keep the battery from getting cold it would loose its capacity Let the battery warm up before charging Charge batteries in stored vehicles every month DEFECTIVE BATTERY Check specific gravity of each cell if a cell is shorted voltage drop may occur only when there is current 37 Maintenance BATTERY CHARGER WARNING Always unplug the AC and DC electrical cords before attempting any repairs to the charger CHARGER DOES NOT TURN cord of portable chargers must be disconnected from batteries after every charge to restart Check dc fuse links Check battery voltage at the battery connector Check ac outlet and cordset Replace electronic control RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT REGISTER Check dc fuse links C
54. lic controls and 4HP pump e Fight 6V 220AH deep cycle batteries e Roll out battery tray e 48V 25A Lestronic II charger Automotive differential e Curtis PMC electronic speed control e Curtis 802 battery discharge indicator e 48V headlight tail brake lights and horn e Hydraulic disc brakes on all four wheels e Front and rear leaf spring suspension e 5 70x S L R D tires e 1000 16 platform capacity 500 165 extended platform capacity The 4805 carries two people up to 8 MPH for faster response to maintenance or emergency sites It is fully self contained and able to move over railroad crossings and rough terrain This 1s due to its use of large tires and automotive leaf springs in the front and rear Motrec even offers the availability of special boxes on the platform for airport and warehouse needs 212 OPERATION 13 Description WARNING Before operating this machine operator must carefuly read the safety instructions in this manual Failure to follow safety instructions may result in severe injury or death PRELIMINARY INSTALLATIONS Remove all packing materials and Inspect for possible damage during shipment Report damage immediately to the person delivering the equipment 2 If side railings are not installed install side railings on four sides of the platform Pin front and rear rails to the sides with clevis pin provided Ch
55. me procedure fill the master cylinder with brake fluid DOT 3 clean every fitting and line remove traces of oil apply a continuous pressure on the brake pedal for about five minutes Finally inspect brake lines and fittings for leaks 34 Maintenance FRONT AXLE AND STEERING CAUTION Before maintenance turn off all switches set to neutral set parking brake remove the key and raise the front end of the vehicle supporting it with two jack stands of adequate capacity STEERING INSPECTION Check tire inflation pressure suspension components tie rods straightness tie rod ends play wear play wear in wheel bearings kingpins and bushings REPLACING amp ADJUSTING THE STEERING GEAR Remove the pitman arm steering box makes 6 5 turns center the steering gear 3 25 turns from either side Align the front wheel straight Install the pitman arm TOE IN ADJUSTEMENT With the wheels in straight forward direction measure the inside left to right distance between the front tires at the front and rear of the tires Turn the rear tie rod until the distances are equal and tighten the two lock nuts on the tie rod REMOVING amp GREASING OF FRONT HUBS required once a year Remove dust cap and cutter pin unscrew nut remove hub Inspect bearings and races for wear and replace worn bearings Replace the seal Pack the hub with wheel bearing grease and re assemble
56. nect potentiometer terminals Check the resistance between terminals Other causes of lower speed dragging brakes cold temperature higher differential oil viscosity INTERMITTENT OPERATION A bad potentiometer is the most probable cause of the following acceleration 1s not constant maximum speed is erratic sudden stop after a bump or shock erratic starts requiring several pedal cycles A bad F R contactor is also a probable cause of the following sudden stop after a bump or shock would not start to move at times Erratic starts could also be the cause of a misadjusted potentiometer or micro switch the pot signal must be less than 50 ohms when the micro switch turns on PMC has HPD safety feature that prevents the vehicle from moving if the accelerator pedal is depressed before the key switch 1s ON and seat switch 1s activated PMC may also have an SRO safety feature that prevents the vehicle from moving if the F R switch 18 activated before turning on the key switch and activating the seat switch The vehicle stops on a steep and long ramp or while towing a heavy load the circuit breaker has open to prevent motor overheating and will reset automatically after one minute The 15 also equipped with an internal thermal protection that cutback the current until the PMC has cooled down 40 Maintenance NO MOTION Make sure that the PMC surface 15 clean and dry check th
57. o compensation will be allowed for delays To initiate warranty coverage on any MOTREC vehicle the Dealer must complete and return the Sales Installation R eport 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 constitut
58. one direction and strong in the other way Check the resistance across the circuit breaker If not 0 ohms replace the circuit breaker Check PMC First disconnect battery B and B then PMC B and M Check the internal diode between B and M terminals using a diode tester If no such instrument 16 at hand use ohmmeter the reading should be weak in one direction and strong in the other way If the internal diode 15 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 41 Maintenance SCISSOR TROUBLESHOOTING NO LIFT MOTION pump not operating POSSIBLE CAUSES 1 2 Q Blown fuses Dead battery Battery contacts Electrical circuit defective Worn brushes Shorted armature Defective motor contactor Defective emergency stop switch or coil Defective KEY switch Defective UP switch REPAIR PROCEDURES l 2 NO FAST LIFT pump not operating POSSIBLE CAUSES l Electrical circuit defective 2 Worn brushes 3 4 Defective pump relay coil or switch Defective motor contactor perpe E Check fuse and replace if necessary Check fuse and replace if necessary Check and charge battery as directed in maintenance section Check battery disconnects Refer to electrical schematic Replace brushes and springs Replace motor Replace contactor Replace
59. output is allowed optional feature V Emergency reverse enhances plugging current when belly button is acti vated on walkie type applications optional feature lt Delayed bypass 1A output drives a bypass contactor optional feature V X Forward reverse and bypass contactor driver outputs are internally pro tected against shorts in the contactor coils lt Simple installation with no adjustments required V Tin plated solid copper bus bars v Push on connectors for control wiring Familiarity with your Curtis PMC controller will help you to install and operate it properly We encourage you to read this manual carefully If you have questions please contact the Curtis office nearest you Working on electric vehicles is potentially dangerous You should protect yourself against runaways high current arcs and outgassing from lead acid batteries RUNAWAYS Some fault conditions could cause the vehicle to run out of control Jack up the vehicle and get the drive wheels off the ground before attempting these procedures or any other work on the motor control circuitry HIGH CURRENT ARCS Electric vehicle batteries can supply very high power and arcs can occur if they are short circuited Always open the battery circuit before working on the motor control circuit Wear safety glasses and use properly insulated tools to prevent shorts LEAD ACID BATTERIES Charging or discharging generates hydrogen gas wh
60. rease starts at 3 mm 1 8 at 1 5 mm 1 16 for potboxes without the microswitch When adjustment 18 correct tighten the screw holding the lever on the pot shaft then recheck to see that this action did not disturb the adjustment Make sure that the lever is still seated down on the pot shaft below the slight bevel on the end of the shaft 3 Check the resistance with the lever pushed all the way to the other stop It should be between 4500 and 5500 ohms If it is outside this range the potbox is faulty and should be replaced 4 For potboxes equipped with a microswitch check for correct switch operation Use an ohmmeter or simply listen for the slight click the switch makes It should operate when the lever is 1 5 mm 1 16 from the return stop If it does not adjust by loosening the two screws holding the slotted microswitch mounting plate to the stop spacers and moving the plate Recheck the switch operating point after tightening the screws Curtis PMC 1204X 1205X 1209 1221 Manual b 24 Spare Parts SPARE PARTS 58 Spare Parts BODY j lt y 24 4 I E 1 j F 1 E Ww k EE EN w d _ 59 Spare Parts REF 10 11 12 2314320001 1005003 2803300009 2803300008 2223360001 2363487001 5 2353320001 2662002 2354320001 2569487
61. rnings stickers and replace any if damage 15 found and part of the text can t be read 21 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 5 100000002 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 Never open battery compartment Never open motor compartment Warn people to stay away from wheels and moving or lifting parts Never exceed specified max speed cargo or passenger capacity Drive slowly on ramps in turns in reverse Avoid loose cargo Before turning on key switch and while moving be sure that occupants keep all their body parts inside vehicle ipants 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 remo
62. rol wire If not B replace the F R switch If B turn off the key switch disconnect batteries disconnect power terminals on the F R contactors check the resistance across N C power terminals of the reverse contactor If not 0 ohm change the reverse contactor If 0 ohms switch to forward and check the resistance across the forward N O power terminals If not 0 ohms change the forward contactor 39 Maintenance REVERSE ONLY On SEPEX motor control check the forward signal input on the controller On series wound motor control 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 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 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 discon
63. ruction will cause death personal injury and property damage GENERAL OPERATING RULES SAFETY AND LIMITATIONS Inspect machine before using Do not use machine if it 1s not working properly in any way Check job site for unsafe working conditions Do not operate on uneven or soft terrain Do not raise platform if machine is on an incline Never carry people and or cargo on platform while moving Use machine only for purposes for which it was designed Do not raise platform if stabilizers are not fully extended and lock Do not exceed the load capacity of platform 1000 Ibs and the load capacity of extended deck 500 Ibs An operator of any type of work platform is subject to certain hazards that cannot be protected by mechanical means It is therefore essential that operators be competent careful physically and mentally fit and thoroughly trained in safe operation of this machine DANGER Do not operate machine near power lines Platform and enclosures are not insulated Failure to follow this warning could cause death or personal injury DANGER TIP OVER HAZARDS _ ELECTROCUTION HAZARD THIS MACHINE IS NOT INSULATED MAINTAIN SAFE CLEARANCES FROM ELECTRICAL POWER LINES AND APPARATUS YOU MUST ALLOW FOR PLATFORM SWAY ROCK SAG THIS WORK PLATFORM DOES NOT PROVIDE PROTECTION FROM CONTACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR OTHER HAZARDS DO NOT OVERLOAD DO NOT USE WITHOUT RAILINGS AND
64. s 1204X 1209 and 1221 have identical connections OVERVIEW OVERVIEW Curtis PMC Model 1204X 1205X and 1209 1221 electronic motor speed controllers are designed to provide smooth silent cost effective control of motor speed and torque on wide variety of industrial electric vehicles Like all Curtis PMC 1200 series controllers the 1204X 1205X and 1209 1221 models offer superior operator control of the vehicle s motor drive speed Key features of these controllers include 4 4 Infinitely variable drive and brake control Power MOSFET design provides high efficiency for reduced motor and battery losses and silent operation High pedal disable HPD function monitors throttle status during turn on and prevents operation until throttle has been returned to neutral optzonal feature Thermal protection and compensation circuit provides both under temperature and overtemperature cutback as well as steady current limit throughout the entire operating range Undervoltage cutback function protects against low battery voltage includ ing low voltage caused by external loads More Features gt Curtis 1204X 1205X 1209 1221 Manual OVERVIEW Y Fault detection circuitry monitors battery throttle connections output transistors bypass contactor etc to prevent runaway conditions V Static return to off SRO function requires that forward or reverse selectors be returned to neutral before
65. s security warming labels DO NOT OPERATE THIS EQUIPMENT WITHOUT PROPER AUTHORIZATION AND TRAINING IT IS THE OPERATOR S RESPONSIBILITY TO 1 READ AND COMPLETELY UNDERSTAND ALL DANGERS WARNINGS CAUTIONS AND INSTRUCTIONS ON THE WORK PLATFORM AND IN THE OPERATING MANUAL 2 THE OPERATOR SHOULD BE ASSURED THAT THE WORK PLATFORM HAS BEEN PROPERLY MAINTAINED AND INSPECTED IN ACCORDANCE WITH GOVERNMENT REGULATIONS BEFORE USING IT 3 PERFORM ALL DAILY MAINTENANCE INSPECTIONS DO NOT EXCEED RATED LOAD DO NOT RAISE THE PLATFORM WHEN ON SOFT AND OR SLOPED SURFACE RAISE THE PLATFORM ONLY WHEN ON A FIRM LEVEL SURFACE THE PLATFORM CAN BE LEVELED WITH PROPERLY POSITIONED OUTRIGGERS IF EQUIPPED DO NOT USE WITHOUT RAILINGS GATE ENTRY CHAINS OR RAILING LOCKING PINS SECURED IN PLACE FAILURE TO OPERATE THIS EQUIPMENT IN ACCORDANCE WITH THE OPERATING INSTRUCTIONS ON THIS EQUIPMENT AND IN THE OPERATING MANUAL COULD RESULT IN SERIOUS INJURY OR EVEN DEATH 106704AC 4800012F Located on left side be on lower control station EMERGENCY DOWN 6587 4800012A Located on left side beside emergency down handle UNLOCK 4800012V Located on left side beside unlock main lever THIS WORK PLATFORM TO BE USED BY TRAINED AND AUTHORIZED OPERATORS ONLY IT 15 THE OPERATORS RESPONSIBILITY TO 1 READ AND UNDERSTAND ALL CAUTION AND DANGER WARNINGS OPERATING MANUAL 2 PERFORM DAILY MAINTENANCE INSPECTIONS 3
66. ss use two opposing wrenches This double wrench technique will help avoid putting stress on the bus bars which could crack the seals Always use insulated wrenches 2 Inspect all seals at the front and back of the controller If necessary use a moist rag to wipe these areas clean enough so that you can see the seals Look for cracks and other signs of seal damage If the seals are intact clean the controller thoroughly either by washing it off or by wiping it clean with a moist rag Power must not be reapplied until the controller terminal area is completely dry If the seals have been damaged there are several possible causes Perhaps the double wrench technique was not used when the cables were installed Perhaps the vehicle s environment requires that the controller be better protected either by mounting it in a different location or by installing a protective cover Damaged seals can lead to faulty operation We strongly recom mend replacing controllers that have faulty seals Adjustment Some controllers allow adjustment of the plug braking current current limit and acceleration rate settings The adjustment pots on these models are located as shown in Figure 16 Curtis 1204X 1205X 1209 1221 Manual 55 22 MAINTENANCE amp ADJUSTMENT Fig 16 Adjustment pots CURRENT LIMIT ADJUST CCW lower current limit PLUG CURRENT AD
67. 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 resistor for a few seconds across B and After cleaning the power must not be reapplied until terminal areas are thoroughly dry On EE Rated vehicles make sure that the control box 1s 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 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 20 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 wa
68. tion only and controls the speed of the vehicle FOOT BRAKE PEDAL It is designed for right foot operation only The brake force 15 proportional to the pressure on the pedal PARKING BRAKE Pull handbrake lever to apply Never park the vehicle on an incline Always turn off all switches set the F R selector to neutral set the parking brake and remove the key before leaving the vehicle 17 CONTROLS IDENTIFICATION PLATFORM PUSH BUTTON SWITCH Pull the emergency stop button on the lower control station to turn ON platform This switch cuts all power to the platform when it 1s pushed Pull the emergency stop button on the upper control box for UP DOWN operation STABILIZERS The stabilizer control switch 1s located on lower control station FOLD DOWN GUARDS Before lifting the platform raise the guards and lock with pins at each corner EXTENDING PLATFORM Remove the lock pin push the platform forward and lock with pin Figure 8 Figure 8 Extended platform UP DOWN Stabilizers must be fully extended UP DOWN switches are located on the upper control box and the lower control station Manual down control handle 18 located on the left side 18 Maintenance MAINTENANCE 19 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 B
69. to prevent overturn and trailer Jack knife Drive slower and start applying brakes sooner on inclines to adjust for longer stopping distance e Use extra care and drive slowly in reverse in congested areas or on wet or slippery ground e Keep to the right under normal conditions Maintain a safe distance from all objects Slow down and sound the horn when approaching a corner or other blind intersections e Before leaving the vehicle park on a level ground flat surface turn off all switches set the forward reverse switch to neutral set the parking brake remove the key Do not park the vehicle on an incline e Before battery charging park the vehicle in 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 E Safety USE OF NOTES CAUTIONS AND WARNINGS NOTE additional information to further explain instructions CAUTION Failure to follow instruction could cause damage to equipment WARNING Failure to follow instruction could cause death personal injury and property damage DANGER Failure to follow inst
70. 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 4 POINTS TENSIONING Check the force F required to provide deflection of 1 8 If the measured force 15 less than 15 Ibs then lengthen centre distance C P SPAN LENGTH EN q DEFLECTION INJ C CENTER DISTANCE 2 33 Maintenance HYDRAULIC BRAKES DRUM BRAKES Remove brake drums and check linings wear the linings should have thickness exceeding 1 16 1 5 mm Turn the brake adjustment to reduce the clearance between lining and drum but avoid contact or drag when the wheels are turned and the pedal is released DISC BRAKES Check linings for excessive wear the linings should have thickness exceeding 1 16 1 5 mm Disc brakes are self adjusting BRAKE PEDAL If the brake pedal becomes soft or spongy may have entered the hydraulic system and the brake system has to be bled I 2 QE fill the master cylinder with brake fluid DOT 3 bleed front callipers one time by having someone applying 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 sa
71. ve the key 5 100000001 Operators Check List Inspect and or test the following daily or at the beginning of each shift THIS ELEVATING WORK PLATFORM HAS BEEN DESIGNED 1 Operating and emergency controls 2 Safety devices AKD TESTED 10 THE FOLLOWING REQUIREMENTS f 4 Tir 14 32 0 3 Personal protective devices 4 Tires and wheels CSA CAN3 B354 2 OR 3 M82 _ Outriggers if equipped and other 6 Air hydraulic and fuel OHSA ONT REG 213 91 structures system s for leaks AS 1418 10 1996 IT IS THE RESPONSIBILITY OF DEALERS OWNERS USERS OPERATORS LESSORS LESSEES CONFORM THE 9 Placards warnings control 10 Guardrail system APPLIGABLE SAFETY REGULATIONS FOR THE OPERATION markings and operating manual s THIS ELEVATING WORK PLATFORM 11 Engine oil level if so equipped 12 Battery fluid level 448000 1 20 13 Hydraulic reservoir level 14 Coolant level if 50 equipped 106691AB 44800012D 22 Maintenance Respectively forward reverse selector and light switch marking Key switch marking LIFT F R 48000125 Scissor security warning labels located on both side KEEP CLEAR 4800012L Striped marking tape 4 4800012W Stabilizers security warning label Each faces sides and rear Striped marking tape 3 30102 23 Maintenance Platform capacity warning labels located on both side 1000 LBS MAX CAP 480
72. w control out of adjustment 2 Friction in structural members 3 Obstruction in hydraulic hose 4 Defective down valve UNIT WILL NOT DESCENT POSSIBLE CAUSES 1 Down signal not applied to down solenoid 2 Defective down coil 3 Defective down valve REPAIR PROCEDURE l 2 Charge battery see Maintenance section Perform visual inspection and ensure all connections are secure 3 Refer to electrical schematic 4 Replace damaged members as necessary see visual structural inspection in Maintenance section 5 Replace defective hydraulic hose 6 Replace hydraulic cylinder 7 Replace pump see Maintenance section 8 Replace brushes 9 Check on cylinder and manifold Check V5 on cylinder 10 Replace high speed valve or coil 11 Tighten connection or filter 12 Replace valve 13 Replace valve REPAIR PROCEDURE 1 Adjust see Maintenance section 2 Check for damaged members and cracked welds see Maintenance section Replace damaged structural members This 1s be done by factory authorized personnel only 3 Replace defective hose 4 Replace valve REPAIR PROCEDURE 1 Check fuse Check battery charge Check electrical circuitry Refer to electrical schematic 2 Replace coil 3 Replace valve Maintenance UNIT CREEPS DOWN POSSIBLE CAUSES REPAIR PROCEDURE 1 Damaged seal in lift cylinder 1 Replace hydraulic cylinder see 2 Defective down valve Maintenanc
73. y leads After cleaning the power must not be reapplied until terminal areas are thoroughly dry BATTERY LEADS AND CONNECTORS Check for loose connections damaged cables acid spill loose terminal posts quarterly BATTERY POST CORROSION If corrosion is present on battery posts remove the cable connectors use a wire brush to remove particles and then clean them with a cloth that has been moistened with ammonia ELECTROLYTE LEVEL Does not apply to sealed battery Disconnect battery connectors on roll out or lift out installations Make sure the battery roll out tray 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 10nized 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 2 36 Maintenance BATTERY MOUNTING loose battery increases damaging effects of vibrations and is more prone to short out BATTERY DISCHARGE LIMIT Discharging below 20 state of charge cuts down the battery and the number of cycles availab
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