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MAINTENANCE MANUAL

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1. BATTERY CAPACITY Analog Voltmeter 12 24V 36 48V 3069007 2469002 3669002 HOBBS Gauge 24V 2469026 36V 3069038 48V 4869037 DC DC converter 10A 12 A8V 3069019 DC DC Converter 25A 12 48V 3124000002 72 80V 3124880001 Wiper motor 12V 24V 3113000001 486211 Wiper arm 2800000001 Wiper blade 14 Blade 18 Blade I Pantograph wiper arm 246233A 2800000002 2800000003 Pantograph wiper blade 246233 Cab heater 12V 36V 48V 3103300001 3669008 4869020 3669006 amp 12V Dome light 12V Fan 3669013 42 Headlamp 12V 3111300001 Bulb 12V 3111300002 Red Pilot light 12V 246212 Bulb 12V 246212B e Back up alarm or Motion beeper 12 48V 3100000001 72 80V 3105720001 12 24V Adjustable 3100000002 Spare Parts BATTERY DISCHARGE INDICATOR HOBBS This indicator monitors the residual capacity of batteries Operating hours Status of service down counter The residual capacity of the battery is monitored via an 8 LED bar display When the left red LED lights the batteries must be charged to avoid damage The LED display starts flashing as a pre warning signal The lower voltage limit is adjustable via potentiometer on the rear jF JG JH J EK gt 1 68 1 93 In order to activate a new adjustment the unit has to be reset 2 35V cell rese
2. B EN 55011 Radio disturbance characteristics Class A AEON kio Flash YELLOW EN 61000 3 2 Limits for harmonic current emissions al Flash Bargraph Flash YELLOW EN 61000 3 3 Limits of voltage fluctuations and flicker lt 80 Charge Indicator Short Flash GREEN _ gt 80 Charge Indicator Solid YELLOW Long Flash GREEN _ EN 61000 4 2 Electrostatic discharge immunity 199 Charge diemor So GREEN 1 61000 4 3 Radiated radio frequency EMF immunity WA FO ENG10004 4 Electrical fast transient burst immunity LED Bargraph 61000 4 5 Surge immunity Bat Temp Compensation Automatic Optional 61000 4 6 Gonducied immunity Maintenance Mode Auto restart if V 2 1Vpc or 30 days elapse EN 61000 4 11 Voltage variations immunity Installation Instructions WARNING output of chargers with greater than 48V may pose an energy and or shock hazard under normal use These units must be installed in the host equipment in such a manner that the output cable and battery connections are only accessible with the use of a tool by qualified personnel 1 Determine Mounting Location While its sealed nature allows the charger to be mounted virtually anywhere the choice of mounting location and orientation is extremely important For optimum performance and shortest charge times mount the charger in an area with adequate ventilation The charger should also be mounted i
3. Algorithm will display for 11 seconds Crown CR325 dv dt b To change algorithm touch positive Deka 8GGC2 Gel connector during the 11 second display generic flooded CP dv dt period to the battery pack s positive 8 Concorde 1xxAh AGM terminal for 3 seconds and then remove Trojan J305 dV dt the Algorithm will advance after 3 E DEKA 8631 Gel seconds Repeat until desired Algorithm 5 Trojan 30XHS is displayed A 30 second timeout is ww US Battery US2200 extended for every increment Troian T 105 Incrementing beyond the last Algorithm Table 1 moves back to the first Algorithm After desired Algorithm is displayed touch the charger connector to the battery positive until the output relay is heard to click 10 seconds algorithm is now in permanent memory c Remove AC power from the charger and reconnect the charger positive connector to the battery pack It is highly recommended to check a newly changed algorithm by repeating step 4 above Product warranty is two years please contact dealer of original equipment for warranty service Note This is a Class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures Aug 2006 9 Delta Q Technologies Corp All rights reserved PN 710 00xx Rev 1 V1 16 40 Spare Parts Strobelight polemount Amber 12 80V 3116000001 Red 12 80V 2469001 Blue 12 80V 3690008
4. On a series wound motor control a bad reverse contactor is the most probable cause of the problem Switch to reverse and check voltage on the reverse control wire If not B replace the F R switch If B turn off the key switch disconnect batteries disconnect power terminals on the F R contactors check the resistance across N C power terminals of the reverse contactor If not 0 ohm change the reverse contactor If 0 ohms switch to forward and check the resistance across the forward power terminals If not ohms change the forward contactor 17 Maintenance REVERSE ONLY On a SEPEX motor control check the forward signal input on the controller On a series wound motor control a bad forward contactor 1s the most probable cause of the problem Switch to forward and check the voltage on the forward control wire If not B replace the F R switch If B turn off the key switch disconnect batteries disconnect power terminals on the F R contactors check the resistance across N C power terminals of the forward contactor If not 0 ohm change the forward contactor If 0 ohms switch to reverse and check the resistance across the reverse N O power terminals If not 0 ohms change the reverse contactor TRAVEL AT REDUCED SPEED Check batteries Turn off all switches and disconnect charger Wear face shield and gloves Do not disturb any battery connection to avoid sparks Check the specific gravity of each cell Cold batteries
5. highly discharged batteries or dead cells are the most frequent causes of reduced travel speed Check potentiometer Turn off the key switch disconnect potentiometer terminals Check the resistance between terminals Other causes of lower speed dragging brakes cold temperature higher differential oil viscosity INTERMITTENT OPERATION A bad 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 15 depressed before the key switch is ON and seat switch is activated PMC may also have an SRO safety feature that prevents the vehicle from moving if the F R switch 15 activated before turning on the key switch and activating the seat switch The vehicle stops on a steep and long ramp or while towing a heavy load the circuit breaker has open to prevent motor overheating and will reset automatically after one minute The PMC is also equipped with an internal thermal protection th
6. Strobelight cab mount Amber 12 48V 3116250001 Red 12 48V 3069026 Blue 12 48V 3069014 Amber 72 80V 3116720001 Red 72 80V 3116720002 Blue 72 80V 3116720003 Amber turn lamp 12V 3069020 Bulb 12V 3069021 Multi LED amber turn lamp Round Light 3111000010 Grommet 3111000008 Plug 3111000009 Red Tail Brake light Grommet 3269001 Plug 246012A 12 2469021 24 2469022 MOTREC ILLUSTRATED ACCESSORIES Red Tail Brake light Housing Bulb 12V Back up lamp Grommet 12V 24V Clear lamp 12V Bulb 12V 3069012R 3117240001 3269001 3669012 3669012A 3069012 1269008 Pedestral head lamp 12V Bulb 12V Bulb 24V Headlight Left Right Bulb H L Bulb Turn Bulb Mark 2569001 2569001B 4469001 3111480003 3111480004 3111480006 3111480008 3111480007 Headlight Left Right Bulb H L Bulb Turn Bulb Mark 3111480003 3111480004 3117480001 3117480003 3117480002 Horn button VIP 2330014 Horn button column mount 246210 Horn button dash mount 266210 LE 3109250001 Turn signal switch 246050 Multi LED Red Tail Brake Light 3111000006 Grommet 3111000008 Plug 3119000009 Horn button Limit switch 3030015 Multi LED Back up Light 3111000007 Strobe light 3111000013 Grommet 3111000008 Plug 3119000009 Horn 12V 246003 24V 246013 Red Tail Brake light 12V 386002 41 1
7. chain drive WHEEL BEARINGSPLAY TIGHTEN NUTS BOLTS electric terminals drive steering brakes suspension body 11 Maintenance ACCELERATOR GEAR Remove the cover Backlash between gears must be reduced to a minimum by sliding holder use locktite 262 to lock the three screws When the plastic gear 1s fully depressed a small backlash must remain between the gears When the plastic gear is released its rear portion must not exceed the pedal case MICRO SWITCH The micro switch must deactivate the on off solenoid when the accelerator 15 released turn the adjusting screw shown on figure below to adjust the micro switch height POT Remove the terminals 2 and 3 on PMC to measure resistance signal When the micro switch is activated the signal must be less than 50 ohms When the front portion of the pedal 15 fully depressed the signal must be more than 4600 ohms To modify the resistance turn the adjusting screw to change the micro switch height see figure below Proceed with the same verifications after the accelerator cover is on and then connect terminals 2 and 3 POTENTIOMETER BRACKET AUXILIARY SWITCH IS WIRED N O WITH BLUE LEAD TO COM amp ORANGE LEAD TON O CIRCUIT THE GREEN LEAD IS GROUNDED AUXILIARY SWITCH IS SHOWN WITH THE TREADLE IN THE UP POSITION SWITCH WILL ACTUATE AT BEGINNING OF TREADLE STROKE SYMBOLS COM N O amp N C ARE TERMIN
8. until a minimum voltage is reached If the charger is used in an off board application and the charger is waiting to be plugged into a battery pack the charging algorithm number will be displayed for 11 seconds see Check Change Charging Algorithm before ultimately displaying an under voltage fault fault disappears when plugged into battery pack Once a minimum battery voltage is detected the charger will enter the bulk charging constant current stage Models 912 xx0x will display the current to the battery on the bargraph and Model 912 xx1x will flash its LED GREEN off more than on to indicate 8096 charge status The length of charge time will vary by how large and how depleted the battery pack is the input voltage the higher the better and ambient temperatures the lower the better If the input AC voltage is low below 104VAC then the charging power will be reduced to avoid high input currents Models 912 xxOx AC LED and Models 912 xx1x single LED both flash YELLOW If the ambient temperature is too high then the charging power will also be reduced to maintain a maximum internal temperature Models 912 xx0x bargraph flashes and Models 912 xx1x single LED flashes YELLOW When the battery is at approximately 80 state of charge the bulk stage has completed and an gt 80 charge indication is given Models 912 turn on the 80 LED and Models 912 xx1x will fiash its LED GREEN on more than off In the next phase known as the ab
9. 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 key switch to OFF lift the wheels off the ground and secure with jack stands of adequate capacity identify and disconnect battery leads PERIOD DAY WEEK MONTH QUART YEAR 2 YEARS CHECK PERFORM HOURS 20 50 200 1000 2000 MECHANICAL DAMAGE OIL LEAKS X J REVERSE ALARM DEADMAN SWITCH X CHECK FILL BATTERIES add distilled water to cover plates Fill to the recommended level after the batteries have been fully charged Se sss Check brake adjustment instructions ISTEERINGFORPLAY FOR ISTEERINGFORPLAY BELTS AND PULLEYS 10 165 force to produce 1 8 deflexion pulleys alignment CHAIN AND SPROCKETS require approximately 1 4 deflexion sprockets alignment CLEAN TIGHTEN WIRE TERMINALS X WASH BATTERY TOP WITH WATER X NEN MOTOR BRUSHES FOR WEAR EE zx 1 eer FT see accelerator instructions BRAKE MECHANICAL LINKAGES 5 j P BRAKE LININGS FOR WEAR J LUBRICATE brake pedal steering column
10. installed inline to prevent damage Shorting or drawing more than 1A may damage charger and void the warranty b Securely fasten the black ring terminal from the charger to the negative terminal NEG NEGATIVE of the battery pack c Check that the correct charge algorithm is being used refer to section 4 Securely fasten the red ring terminal to the positive terminal POS POSITIVE of the battery pack 1A Charger Interlock Internal yc B Output O B BLKANHT Figure 1 4 Check Change Charging Algorithm The charger comes pre loaded with algorithms for batteries as detailed in Table 1 If your specific battery model is not listed please contact Delta Q Each time AC power is applied with the battery pack NOT connected the charger enters an algorithm select display mode for approximately 11 seconds During this time the current Algorithm is indicated on the 80 LED Models 912 xx0x or on the single LED Models 912 xx1x A single digit Algorithm is indicated by the number of blinks separated by a pause A two digit Algorithm is indicated by the number of blinks for the first digit followed by a short pause then the number of blinks for the second digit followed by a longer pause To check change the charging algorithm a Disconnect the charger positive Fs Battery Type connector from battery pack Apply AC power and after the LED test the Si Concorde 2xxAh AGM
11. more sensitive to overturn and jack knife when traveling on inclines or when carrying a heavy load e Always drive straight up and down the face of an incline never across the face to prevent overturn and trailer jack knife Drive slower and start applying brakes sooner on inclines to adjust for longer stopping distance e Use extra care and drive slowly in reverse in congested areas or on wet or slippery ground e Keep to the right under normal conditions Maintain a safe distance from all objects e Slow down and sound the horn when approaching a corner or other blind intersections e Before leaving the vehicle park on a level ground flat surface turn off all switches set the forward reverse switch to neutral set the parking brake remove the key Do not park the vehicle on an incline e Before battery charging park the vehicle in a well ventilated area set for Do not operate it when charging To interrupt a charging cycle disconnect the AC plug disconnecting the DC plug or a battery terminal or operating the vehicle could damage the charger and produce a spark battery explosion and acid splashing e Use another driver to steer this vehicle while it is towed Be sure the driver uses brakes when you slow or stop the towing vehicle Do not exceed 5 MPH or carry any passenger while towing this vehicle Instructions OPERATING INSTRUCTIONS The owner shall ensure that the operator understands the operating characteristics of th
12. responsible for the control of the vehicle while driving and must always evaluate and care for all peculiar situations that he or she may meet while driving The driver assumes the inherent hazards related to this activity The vehicle is designed for off road use only MOTREC disclaims any liability for incidental or consequential damages to include but not be limited to personal injury or property damage arising from vehicle misuse lack of maintenance or any defect in the vehicle It is the responsibility of the Owner of the vehicle to make sure that the service technicians are properly trained as required by OSHA and ANSI B56 Service technicians shall read understand and follow instructions in the MOTREC manual before servicing the vehicle Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect the vehicle MOTREC prohibits and disclaims responsibility for any vehicle modification altering the weight distribution and stability increasing the speed or affecting the safety of the vehicle Such modifications can cause serious personal injury or property damage for which MOTREC disclaims any responsibility For Owners that are located outside North America the warranty period starts the date of shipment from the factory and the defective parts must be returned at the Owner s expense to MOTREC prior to warranty repair 18 01 2008 Table of contents TABLE OF CONTENTS INSTRUCTIONS SAFETY WARN
13. www deita q com Attention utiliser seulement sur les batteries 72V avec un algorithme appropri au type sp cifique de batterie voire le manuel D autres types de batteries pourraient clater et causer des blessures ou dommages Les batteries peuvent produire des gaz explosives en service normal Ne jamais fumer pr s de la batterie et viter toute tincelle ou flame nue proximit de ces derniers Fournisser la bonne ventilation lors du chargement Ne jamais charger une batterie gel e Prendre connaissance des mesures de pr caution sp cifi es par le fabricant de la batterie p ex v rifier s il faut enlever les bouchons des cellules lors du chargement de la batterie et les taux de chargement recommand s Information de S curit lectrique Danger Risque de chocs lectriques Ne pas toucher les parties non isol es du connecteur de sortie ou les bornes non isol es de la batterie Toujours connecter le chargeur une prise de courant mise la terre Ne pas ouvrir ni desassembler le chargeur referer toute reparations aux personnes qualifi s Pas l usage des enfants Tel 604 327 8244 Fax 604 327 8246 The charger will automatically turn on and go through a short LED indicator self test Models 912 xx0x will flash all LED s in an up down sequence and Models 912 xx1x will alternatively flash its LED RED GREEN for two seconds If the charger is connected to battery pack a trickle current will be applied
14. 3 121410 FRONT SPACERS KIT 24 121409 BOLT 5 8 NC X 7 25 123007 TIRE AND TUBE 27 LOCKNUT 5 8 NC 29 Spare Parts REF PART NO 121401 241402 2100000002 121407 121408 AN HANDLE BAR E 2j di i n s Ts in nn t 1 umm as 5 m k 2 L a lo mm d Tm Em e T 4 x 1 0 5 k L LU E z E ez kai lin n DESCRIPTION HANDLE BAR HANDGRIPS BOLT 3 8 NC X 2 LOCKNUT 3 8 NC BUSHING WASHER FORK 30 Spare Parts REAR WHEEL REF PART NO DESCRIPTION 1 LOCK NUT 1 2 NC 2 FLAT WASHER 1 2 3 261403 BALL BEARING 4 2100012001 SPACER 5 123004 SPLIT RIM 6 123007 TIRE AND TUBE 7 2224012001 HUB 8 1010001 DRUM 9 1222002 SPROCKET 54T E 100 ONLY 10 2201012002 SHAFT 11 BOLT 1 2 NC X 5 1 2 E 12 BOLT 1 2 NC X 6 1 2 E 100 ana Spare Parts MOTOR AND DRIVE REF PART NO DESCRIPTION 1 1250001 TWO MOTOR BRUSHES 1250002 TWO MOTOR SPRINGS 124002 1 2 HP MOTOR 24V 124001A 3 4 HP MOTOR 24V 2 122422 DRIVE MOUNT 3 122423 SHAFT 4 122424 PILLOW BLOCK 5 122405 SQUARE KEY 3 16 6 122425 SQUARE KEY 3 16 7 122426 SPROCKET TO SPECIFY 8 122427 PULLEY SPECIFY DIA 9 122428 PULLEY SPECIFY DIA 10 122429 BELT SPECIFY PULLEY 11 BOLT 3 8 NC X 1 1 4 12 LOCKNUT 3 8 NC 13 1022002 C
15. AL MARKINGS AS MARKED ON SWITCH AUXILIARY SWITCH E ADJUSTING SCREW ACTUATOR PIN 12 Maintenance MECHANICAL BAND BRAKES When the brakes are properly adjusted the clearance under the pedal should be 2 inches from the floor when the brakes are applied The rear wheels will also brake equally To adjust the brakes turn the yoke 13 as required 13 Maintenance BATTERY MAINTENANCE WARNING It is the responsibility of the owner of this vehicle to ensure that the service technicians are properly trained read and obey the safety rules and guidelines in this manual ANSI B56 Maintenance operations must be made by properly trained service technicians only Before any maintenance work park the vehicle on a flat level surface turn off all the switches set to neutral remove the key lift the wheels off the ground and secure with jack stands of adequate capacity Keep charger disconnected while doing any maintenance work Always wear a face shield and scarf when working around batteries Battery emits highly explosive gases do not produce sparks to avoid battery explosion and acid splashing Battery acid causes severe damage to eyes or skin Flush contaminated area immediately with water Use insulated tools to avoid sparks that can cause battery explosion and acid splashing Use two counteracting tools double wrench technique when disconnecting or tightening battery posts Before cleaning or r
16. DSET 15 203248 CORDSET DC NO PLUG 44 085135 CORDSET DC NO PLUG 108 149738 CORDSET DC WITH SILICONE PLUG 093315 CORDSET DC WITH LESTER PLUG 094915 CORDSET DC WITH 50 ANDERSON PLUG GREY 120418 CORDSET DC WITH 50 AMP ANDERSON PLUG RED 086955 CORDSET DC WITH 175 ANDERSON PLUG 161068 CORDSET DC WITH 30 AMP POWER POLE PLUG 083135 PLUG ASSY DC 50 ANDERSON PLUG GREY 040878 PLUG ASSY DC 50 AMP ANDERSON PLUG RED 029575 PLUG ASSY DC 175 ANDERSON PLUG 37 Spare Parts DELTA Q HF CHARGER NO PART NO DESCRIPTION 1 3102240002 24V CHARGER U S BATTERY 3102240003 24V CHARGER LIFELINE BATTERY 3102302001 36V CHARGER U S BATTERY 3102302002 36V CHARGER LIFELINE BATTERY 3102480002 48V CHARGER U S BATTERY 3102480003 48V CHARGER LIFELINE BATTERY 2 3119000011 CONNECTOR C13 38 Spare Parts QuiQ HFIPFC Battery Charger SAVE THESE IMPORTANT N SAFETY INSTRUCTIONS This manual contains important safety operating and installation instructions read before using charger Battery Safety Information Wa rning Use charger only on battery systems with an algorithm selected that is appropriate to the specific battery type Other usage may cause personal injury and damage Lead acid batteries may generate explosive hydrogen gas during normal operation Keep sparks flames and smoking materials away from batteries Provide adequat
17. ER 36708 PLASTICGEAR 367015__ SPRING 2462008 CONNECTOR 31090000004 EMERGENCY PUSH BUTTON LABEL 3109800006 XI HOUR METER CONNECTOR F R CONTACTOR 24V FIRBUSSBARS 246908 STATICSTRAP Consult Motrec Illustrated parts 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 35 Spare Parts BATTERY CONFIGURATIONS 24V CONFIGURATIONS DES BATTERIES 24V 12V Accessories Ground 12V Accessories Ground 12V Accessories Ground E 260 E 262 E 270 E 272 E 240 E 242 E 242 HD E 250 E 250HD 36 Spare Parts AG INPUT GROUNDED PLUG AC CORDSET TIMER KIT LHT ELECTRONIC 00 TAN TAN S M QC l v aH 11 1 CASE GROUND BUILT IN OR PORTABLE 15A CHARGER CAPACITOR HEATSINK ASSEMBLY WITH DICOES WHITE OR RED C OC COROSET _ BLACK 2 ro BLACK 2 ro 2 BATTERIES TRANSFORMER T TAN ela FUSE ASSEMBLY WHITE AMMETER Parts list for LESTRONIC II charger MODEL 09678 TYPE 24LC15 2ET 115 VAC 60 Hz PART NO DESCRIPTION 096255 CASE ASSEMBLY 092628 TRANSFORMER ASSEMBLY 163548 HEATSINK ASSEMBLY WITH DIODES 025635 096625 ELECTRONIC TIMER ASSEMBLY RELAY 044835 041428 CAPACITOR 3 0 MFD 660 VAC 038378 FUSE ASSEMBLY 038948 BUSHING 7W 2 INSULATOR FOR CORDSETS 038228 CORDSET AC 102 072395 COR
18. Follow the maintenance instructions applicable to the type of repair maintenance or service Always wear a face shield and gloves when working around batteries Before opening the battery compartment disconnect the charger turn off all switches and remove the key Batteries emit highly explosive gases which greatly increase when charging do not disturb connections or produce sparks around batteries to avoid a battery explosion and acid splashing Battery acid causes severe damage to eyes or skin Flush contaminated area immediately with water Use insulated tools to avoid sparks that can cause battery explosion and acid splashing Use two counteracting tools double wrench technique when disconnecting or tightening terminals on the battery and the speed controller to avoid cracking the terminal or battery post welds Before cleaning or replacing a battery charger speed controller contactor relay diode or any other component in the power circuit always disconnect the charger turn off all switches remove the key wear a face shield and gloves identify battery polarity and disconnect battery leads discharge the capacitor in the controller with a 10 ohms 25 W resistor for a few seconds across B and B After cleaning the power must not be reapplied until terminal areas are thoroughly dry On EE Rated vehicles make sure that the control box is sealed the static strap makes good contact with the ground the motor is sealed by bands t
19. H Battery Voltage Low auto recover 3 FLASH Charge Timeout the charge did not complete in the allowed time This may indicate a problem with the battery pack voltage not attaining the required level or that the charger output was reduced due to high ambient temperatures 4 FLASH Check Battery the battery pack could not be trickle charged up to the minimum level required for the charge to be started This may indicate that one or more cells in the battery pack are shorted or damaged 5 FLASH Over Temperature auto recover Charger has shutdown due to high internal temperature which typically indicates there is not sufficient airflow for cooling see Installation Instructions 1 Charger will restart and charge to completion if temperature comes within accepted limits 6 FLASH QuiQ Fault an internal fault has been detected If Fault 6 is again displayed after interrupting AC power for at least 15 seconds the charger must be brought to a qualified service depot Maintenance Instructions 1 2 3 For flooded lead acid batteries regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer Follow the maintenance and safety instructions recommended by the battery manufacturer Make sure charger connections to battery terminals are tight and clean Do not expose charger to oil dirt mud or to direct heavy water spraying when cleaning vehicle See fl
20. HAIN 32 Spare Parts ELECTRICAL DIAGRAM SERIES MAIN CIRCUIT DIAGRAMME LECTRIQUE CIRCUIT PRINCIPAL SERIES 2006 04 12 J GAGNON APPROVED DRAWING SERIES PERMANENT MAGNET VSD SERIES PERMANENT MAGNET MAIN CIRCUIT SERIES VERSION AUTHOR WHT WHT BLK O o eu o O x O lt O O RED C NE BLU BLK 33 Spare Parts ACCESSORIES NO DC DC CONVERTER ACCESSOIRES SANS CONVERTISSEUR DC DC CIAOYddY NONDVS f OISA A CISELLEIHE 90 00 ON SNIMVHG YOHLNV LL v0 9002 LO S3IMOSS3D00V NOISHIA FIL ISVILVIHI S3IHOSS39OV LOFMENS ON VIULON cru 59110559026 uo Buipuedep JO AZ Jeune SI eu JOU SI uondo JelJeAUuoo usum jsod eAnisod 195 elleq o 9AnejoJ sod ue je pejoeuuoo si punoJ6 seuosseooy P G RED WHT e RED BLK NUO wa gt 1 ENN m T gt ora gt gt gt 34 Spare Parts PARTS LIST GI BATTERY 1 52 BATTERY CHARGER 3125012001 3125012001 MICROSWITCH _________ 367020 POTENTIOMET
21. INGS FOR OPERATORS OPERATING INSTRUCTIONS MAINTENANCE SAFETY WARNINGS FOR SERVICE TECHNICIANS DECALS AND LABELS PERIODIC MAINTENANCE CHECKLIST ACCELERATOR MECHANICAL BAND BRAKES BATTERY MAINTENANCE BATTERY CHARGER ELECTRICAL TROUBLESHOOTING CURTIS PMC MOTOR CONTROLLER WIRING STANDARD CONFIGURATION MAINTENANCE AND ADJUSTMENT SPARE PARTS BODY BRAKE CONTROLS FRONT AXLE HANDLE BAR REAR WHEEL MOTOR AND DRIVE ELECTRICAL DIAGRAM SERIES MAIN CIRCUIT ACCESSORIES NO DC DC CONVERTER BATTERY CONFIGURATIONS 24V BUILT IN OR PORTABLE 15A CHARGER DELTA Q HF CHARGER MOTREC ILLUSTRATED ACCESSORIES BATTERY DISCHARGE INDICATOR HOBBS CON NA k 10 12 13 14 16 17 20 22 24 26 27 28 29 30 3l 32 33 34 36 37 38 4 43 Instructions INSTRUCTIONS Instructions SAFETY WARNINGS FOR OPERATORS e FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY e tis the responsibility of the owner of this vehicle to train operators to ensure that they understand the operating characteristics of this vehicle including training in vehicle stability and obey the following safety rules and guidelines Owner shall comply with OSHA and ASME ANSI B56 8 amp B56 9 regulations for vehicle use safety rules operator training and certification Do not drive this vehicle unless you are a qualified operator e Do not drive this vehicle under the influence of drugs or alcohol e Do not drive thi
22. MOTREC 100 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1032544 amp UP Printed in Canada One Year Limited Warranty Effective April 25 2005 MOTREC Inc MOTREC hereby warrants to the Original Retail Purchaser Owner that any of its vehicles shall be free from any defect in materials for a period of 90 DAYS while in the possession of such Original Retail Purchaser This warranty I5 NOT TRANSFERABLE to any subsequent Buyer The warranty period is extended to one year or one thousand 1 000 hours which ever first occurs on the electric motor differential parts that bathe in oil and the electronic speed controller MOTREC makes no warranty or representation with respect to the internal combustion engine tires and batteries since their respective manufacturers cover such parts Accessories light gage horn etc electrical contacts switch solenoid contactor relay diodes amp fuses belts amp pulleys filters amp spark plugs lubricants brake linings amp shoes brake drums amp discs seals seats trim and other items subject to wear are not included in this warranty nor is any item that in MOTREC sole opinion shows evidence of neglect misuse abuse collision or alteration This warranty shall not apply to normal maintenance requirements as described in the User Manual and to damages during shipment The latter is the carrier s responsibility No compensation will be all
23. RATION 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 screw driver available from Curtis 3 Replace the socket head screw and nylon seal washer To pre vent stripping do not over tighten Curtis PMC 1204 1205 Manual 25 23 Spare Parts SPARE PARTS 26 Spare Parts BODY REF PART NO DESCRIPTION 1 6105100002 BODY 2 120003 TRIM 3 2339100001 REAR COVER 4 1005003 BUCKET SEAT WITH SLIDE ADJUSTERS 5 1007001 FRONT 410 6 WHEEL 4P SPLIT RIM 1207001 REAR 410 6 WHEEL 4P SPLIT RIM 6 2500250002 DASH PLATE 27 Spare Parts BRAKE CONTROLS 19 REF PART NO DESCRIPTION REF PART NO DESCRIPTION 1 242800 RUBBER PEDAL 14 BOLT 5 16 NC X 1 2 242802 LATCH 15 FLAT WASHER 5 16 3 COTTER PIN 16 242816 SPRING 4 CLEVIS PIN 1 4 X 1 1 2 17 242817 LUBRIFICATION FITTING 5 COTTER PIN 18 LOCKNUT 5 16 NC 6 242806 SPRING 19 CLEVIS PIN 3 8 X 1 7 242807 LEVER 20 COTTER PIN 8 242808 PIVOT 21 122821 ROD 9 BOLT 1 4 NC X 3 4 25 122825 BAND BRAKES 10 LOCKNUT 1 4 NC 26 122826 ADJUSTING SCREW 13 122813 YOKE 3 8 28 Spare Parts FRONT AXLE FRONT AXLE TIRE AND TUBE REF PART NO DESCRIPTION 5 123008 BALL BEARING 22 123017 FRONT SPLIT RIMS 2
24. Reversing is accomplished via two single pole double throw 2xSPDT contactors Coil suppression diodes should be used on the main and forward reverse contactors KSI Wiring The keyswitch input KSI circuit includes input from the keyswitch and from the 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 KSI draws only a very small current a few mA In its simplest form KSI is operated by a keyswitch that turns the vehicle off and prevents unauthorized use The keyswitch should also Curtis PMC 1204 1205 Manual 23 10 MAINTENANCE amp ADJUSTMENT MAINTENANCE amp ADJUSTMENT Curtis 1204 1205 controllers and potboxes require only minimal main tenance 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 occasion ally First remove power by disconnecting the battery and discharge the capacitors in the controller with a light bulb or a 2 10 Q 25 W resistor connected for a few seconds across B B Follow good safety practices get the vehicle drive wheels off the ground wear safety glasses and use insulated tools see page 2 1 Make sure the electrical connections to the controller and to
25. at cutback the current until the PMC has cooled down 18 Maintenance NO MOTION Make sure that the PMC surface is clean and dry check the terminal areas Dust Particles or acid contamination can create current leaks and cause a PMC 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 a switch pin does not read B check wiring or replace the switch Check potentiometer Turn the key switch to OFF disconnect potentiometer terminals Check the resistance across terminals if not within the recommended limits adjust or replace the potentiometer Check for shorts between potentiometer wires and vehicle frame resistance should read at least 1 megohm Check main contactor or solenoid Check voltage across power terminals if not B check circuit breaker or replace the solenoid Turn to on the key switch and activate the seat switch Check voltage across the coil terminals if not B check wiring and interlock switches Check resistance across power terminals if not ohms replace the solenoid Check circuit breaker and SEPEX DIODE Before replacing the circuit breaker check for shorts in the power circuit and c
26. brations and 1s more prone to short out BATTERY DISCHARGE LIMIT Discharging below a 20 state of charge cuts down the battery life and the number of cycles available At 20 state of charge specific gravity of 6V battery should be 1180 and 1220 for industrial battery CHARGING AREA Always charge battery in a well ventilated area set for and approved for charging Never leave a charger connected for more than 20 hours FREQUENCY OF CHARGE When battery is discharged to its 20 state of charge it is best to charge immediately Batteries require a low current equalization charge min 4 hours at least every week to equalize battery cells improve battery performance and life in number of cycles Never leave a charger connected for more than 20 hours STORAGE Keep the battery from getting cold it would loose its capacity Let the battery warm up before charging Charge batteries in stored vehicles every month DEFECTIVE BATTERY Check specific gravity of each cell if a cell 1s shorted voltage drop may occur only when there 1s current 18 Maintenance BATTERY CHARGER WARNING Always unplug the AC and DC electrical cords before attempting any repairs to the charger CHARGER DOES NOT TURN ON Dc cord of portable chargers must be disconnected from batteries after every charge to restart Check dc fuse links Check battery voltage at the battery connector C
27. e steering column or handle bar F R SWITCH Three positions with neutral at center Depress the front part of the rocker switch for forward direction Depress the rear part of the rocker switch for reverse direction Always set switch to neutral turn off all switches set the parking brake remove the key before leaving the vehicle ACCELERATOR PEDAL It is designed for right foot operation only and controls the speed of the vehicle FOOT BRAKE PEDAL It is designed for right foot operation only The brake force 1s proportional to the pressure on the pedal PARKING BRAKE Depress brake pedal and pivot to lock brakes Check pedal lock Never park the vehicle on an incline Turn off switches set to neutral set parking brake remove key before leaving the vehicle 6 Maintenance MAINTENANCE Maintenance SAFETY WARNINGS FOR SERVICE TECHNICIANS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY Owner shall comply with OSHA and ASME ANSI B56 8 amp B56 9 regulations for vehicle maintenance Only qualified and authorized personnel shall be permitted to maintain repair adjust and inspect carriers vehicles tractors and batteries Before any maintenance work park the vehicle on flat level surface turn off all switches remove key lift wheels off the ground and secure with jack stands of adequate capacity Don t connect charger Keep clear from moving parts such as tires sheaves and motor
28. e ventilation during charging Never charge a frozen battery Study all battery manufacturers specific precautions such as recommended rates of charge and removing or not removing cell caps while charging Electrical Safety Information Danger Risk of electric shock Connect charger power cord to an outlet that has been properly installed and grounded in accordance with all local codes and ordinances A grounded outlet is required to reduce risk of electric shock do not use ground adapters or modify plug Do not touch uninsulated portion of output connector or uninsulated battery terminal Disconnect the AC supply before making or breaking the connections to the battery while charging Do not open or disassemble charger Do not operate charger if the AC supply cord is damaged or if the charger has received a sharp blow been dropped or otherwise damaged in any way refer all repair work to qualified personnel Not for use by children Operating Instructions Always use a grounded outlet When using an extension cord avoid excessive voltage drops by using a grounded 3 wire 12 AWG cord 4 2 m Product Manual for QuiQ 912 24xx 36xx 48xx 72xx Unit 3 5250 Grimmer St Burnaby BC Canada V5H 2H2 INFORMATIONS IMPORTANTES DE SECURITE Conserver ces instructions Ce manuel contient des instructions importantes concernant la s curit et le fonctionnement Information de S curit de la Batterie
29. eplacing a battery discharge the capacitor in the controller with a 10 ohms 25 W resistor for a few seconds across B and B identify battery polarity and disconnect battery leads After cleaning the power must not be reapplied until terminal areas are thoroughly dry BATTERY LEADS AND CONNECTORS Check for loose connections damaged cables acid spill loose terminal posts quarterly BATTERY POST CORROSION If corrosion is present on battery posts remove the cable connectors use a wire brush to remove particles and then clean them with a cloth that has been moistened with ammonia ELECTROLYTE LEVEL Does not apply to sealed battery Disconnect battery connectors on roll out or lift out installations Make sure the battery roll out tray 1s provided with stops before rolling out Fill with distilled water Daily charged batteries normally require watering once a week Under watering leads to a shortened battery life Over watering leads to battery corrosion Be careful not to overfill any cell to avoid electrolyte to be forced out while charging Fill each cell to plate level with distillated or de ionized water before battery charging When the battery is charged the fluid expands and can seep out if overfilled Refill each cell after full charge when the fluid has expanded to its maximum level Reinstall battery caps before charging 14 Maintenance BATTERY MOUNTING A loose battery increases damaging effects of vi
30. he cable protectors are properly installed Keep cables and wires clear from mechanical and rubbing action Make sure that cable insulation is free from cutting or visible damage Make sure that EE Rated cable protectors are properly installed Before replacing a fuse or circuit breaker identify the cause of failure and repair Programmable controllers must be programmed using the parameter settings in this service manual before connecting the motor to avoid sudden vehicle movement and accident Maintenance Do not try to increase motor speed by changing parameter settings in the speed controller it can cause accident and severe damage to the motor SEPEX speed controls are protected by a diode in the power circuit to filter inductive loads in the event of a sudden power interrupt Some speed controllers require a diode to filter inductive loads on the KSI input Removing the diodes will cause the speed control failure Before resuming maintenance operations inspect safety warnings stickers and replace any if damage 1s found and part of the text can t be read Maintenance DECALS AND LABELS CAUTION The images included in this section depict the decals markings installed on the vehicle It is of the utmost importance that theses decals markings remain unaltered and readable Else the sticker or the part baring the marking has to be replaced Dashboard security warning label Operation of this vehicle is restricted to au
31. heck ac outlet and cordset Replace electronic control RELAY CLOSES AND TRANSFORMER HUMS BUT AMMETER DOES NOT REGISTER Check dc fuse links Check the continuity of the dc output cord ammeter diodes and all connections in the dc circuit Check diodes Check capacitor rapidely increasing resistance SINGLE CHARGER FUSE BLOWS Disconnect and check diodes BOTH FUSE LINKS BLOW Check the battery pack and battery connector polarity Disconnect and check diodes CHARGER OUTPUT IS LOW Disconnect and check diodes Can be caused by a transformer failure AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES Check the battery pack CHARGER DOES NOT TURN OFF Check specific gravity in each battery cell As much as 16 hours may be required to properly charge heavely discharged new or cold batteries Replace electronic control AC LINE FUSE OR CIRCUIT BREAKER BLOWS Check ac cordset Check ac line fuse rating Replace electronic control Can be caused by a transformer failure 16 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 secti
32. heck the SEPEX diode in the power circuit using a diode tester If no such instrument is at hand use an ohmmeter the reading should be weak in one direction and strong in the other way Check the resistance across the circuit breaker If not ohms replace the circuit breaker Check PMC First disconnect battery B and B then PMC B and M Check the internal diode between B and M terminals using a diode tester If no such instrument is at hand use an ohmmeter the reading should be weak in one direction and strong in the other way If the internal diode is defective the PMC must be replaced Check the Motor First disconnect battery B and B disconnect power terminals and check the motor armature and field for opens 19 Curtis Speed Controller CURTIS PMC MOTOR CONTROLLER 20 MANUAL 21 CURTIS 217717 1204 5 MOTOR CONTROLLERS 1999 CURTIS INSTRUMENTS INC DESIGN OF CURTIS 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 1204 1205 Manual p n 98690 Rev B May 1999 WIRING WIRING CONNECTIONS Low Current Three 1 4 push on terminals are provided KSI i throttle for the low current connections to the KSI inputs 3 and throttle inputs For the control wiring 0 75 mm 18 AWG vinyl insulated stranded wire is rec ommended CONNECTIONS High Current Four tin plated solid copper bus bars are provided for the high current co
33. ip side for Product Specifications and Installation Instructions for qualified personnel 39 Spare Parts Specifications Voltage nom __ Voltage mnax V _ Currentmax A Mechanical models Dimensions 28 0 x 24 5 x 11 0 om 11x 9 7 x 4 3 Battery Type Reverse Polarity Short Circuit Electronic protection auto reset Electronic current limit AC Inp Voltage max Vrms Frequency Hz Current max Arms Current nominal Arms AC Power Factor 12A 104VAC reduced 20 lt 104V gt 0 98 at nominal input current models iene Min _10 120 5 230VAC _ Weight ____ 5 kg lt 11 Ibs w standard output cord Environmental Enclosure 46 Operating 30 C to 50 C 22 F to 122 F derated Temperature above 30 below 0 C Storage Temperature 40 C to 70 C 40 F to 158 F AC input connector DC output connector IEC320 C14 require 21 8m localized cord OEM specific w 12AWG wire Regulato EN 60335 1 2 29 Safety of Appliances Battery Chargers UL2202 EV Charging System Equipment UL 1564 2nd Edition Industrial Battery Charger CSA C22 2 No 107 2 Battery Chargers Industrial FCC Part 15 ICES 003 Unintentional Radiators Class A
34. is vehicle and obeys the safety instructions in this manual and ANSI B56 standard Do not drive this vehicle unless you are a certified operator as required by OSHA BEFORE USING VEHICLE Before turning on key switch set to neutral check for any visible damage check brake pedal BATTERIES Never open the battery compartment unless you have received proper training for battery maintenance Batteries emit explosive hydrogen gas that can be ignited by a spark or loose terminal Battery acid causes severe damage to eyes or skin Flush the contaminated area immediately with water BATTERY CHARGER Park the vehicle in a well ventilated area for battery charging Most battery chargers come with an electronic control that starts when the charger is plugged and stop when the battery 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 1s at the last position on the left the batteries must be recharged A flashing light warns the operator that further discharge will damage batteries See HOBBS indicator instructions KEYSWITCH Depress brake pedal and turn the key switch clockwise for on position Always turn off all switches set the F R selector to neutral set the parking brake remove the key before leaving the vehicle HORN Depress the horn button on th
35. n an area that will be relatively free of oil dirt mud or dust since accumulations within the fins of the charger will reduce their heat dissipating qualities Optimal cooling also occurs when the charger is mounted on a horizontal surface with the fins vertical More airflow from below the charger will help cool the fins so mounting above open areas or areas with cut outs for airflow is desirable Contact Delta Q for information on other mounting orientations As the charger may get hot in operation the charger must be installed such that risk of contact by people is reduced The charger s AC plug must be located at least 18 above the floor ground surface and the status display must be visible to the user 2 Mounting Procedure Mount the charger by the mounting plate using appropriate fasteners i e 1 4 or M6 with locking hardware For UL2202 compliance a 12AWG green bonding wire with ring terminals must be attached from the bonding stud located on the front of the charger identified by to the vehicle frame The vehicle connection must be made using corrosion resistant hardware e g a 10 stainless steel machine screw with at least two threads of engagement and if required a paint piercing washer 3 DC Battery Connection Procedure a The green wire outputs battery voltage when the charger is not plugged into AC to provide an interlock function see Fig 1 If used a user supplied 1 fast blow external fuse must be
36. nnections to the battery and motor output to motor field negative connection to battery positive connection to battery and to motor armature plug diode to motor armature The cables used for the battery and motor connections must be heavy enough to carry the high current required A minimum size of 25 mm 4 AWG is recommended 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 connections and could also result in cracked seals around the bus bars Curtis PMC 1204 1205 Manual 2 22 9 WIRING CONTROL WIRING PEDAL FUSE KEYSWITCH INTERLOCKS MICROSWITCH gt O AoA POLARITY PROTECTION POWER WIRING DIODE FUSE PRECHARGE RESISTOR 250 Q 5 W D gt oc 5 i T Fig 6 Basic wiring configuration Curtis PMC 1204 1205 controller WIRING SERIES MOTORS Eigure 6 is a schematic of the configuration shown in Eigure 5 Wired this way the vehicle will plug brake if the direction is changed with the vehicle moving and the throttle applied
37. on in this manual WARNING Before any maintenance work park the vehicle on a flat level surface turn off all switches remove the key lift the wheels off the ground secure with jack stands of adequate capacity disconnect charger Always wear safety glasses Batteries emit highly explosive gases that can be ignited by a spark Before disconnecting a high current terminal turn off all switches disconnect battery charger disconnect batteries Keep clear from moving parts such as tires sheaves and motor PMC SELF DIAGNOSTIC If your PMC comes with a status led use the flashing code to help troubleshooting BATTERY VOLTAGE Make sure batteries are securely connected Measure voltage between and terminals We will call this value B or full battery voltage ACCESSORIES NOT WORKING Check the fuses on the batteries and the DC DC converter Check voltage across and terminals on the battery gage if not B check wiring Turn the key switch ON check voltage between output terminal on the key switch and the terminal on the battery gage if not B replace the key switch Check voltage across DC DC converter output terminals if not 12 Volt replace the converter Depress the accessory switch check voltage across accessory terminals If not 12 Volt replace the switch If 12 Volt replace the accessory FORWARD ONLY On a SEPEX motor control check the reverse signal input on the controller
38. owed for delays To initiate warranty coverage on any MOTREC vehicle the Dealer must complete and return the Sales Installation Report to MOTREC within 30 days after delivery to the Original Retail Purchaser or within 90 days after the delivery date to the Dealer which ever occurs first Failure to follow these procedures will result in considering the warranty coverage effective as of the shipment date from the factory The defective vehicle must be returned at the Owner s expense to an authorised MOTREC Dealer within 30 days after failure The Owner will not be charged for parts and labour required for warranty repairs which must be performed by an authorised MOTREC Dealer only The vehicle will be returned at the owner s expense The Warranty Claim Forms must be completed and returned with the defective part s to MOTREC within 30 days after repair was done No compensation will be allowed for damages caused by vehicle downtime It is the responsibility of the owner of the vehicle to make sure that the driver is properly trained and instructed in the safety features and operation of the vehicle including vehicle stability as required by OSHA and ANSI B56 Operators shall read understand and follow the safety and operating instructions in MOTREC Manual before driving the vehicle Operators shall not be permitted to drive the vehicle unless a complete and adequate training has been provided Driving a vehicle constitutes a hazard The driver is
39. s vehicle on public roads and highways This vehicle is designed to be driven in buildings e The electrical system of this vehicle will make sparks which can ignite inflammable materials Never use the vehicle in hazardous areas where there are inflammable materials explosive dust or fumes in the air e Have your vehicle inspected regularly by trained personnel and cease operation if a malfunction occurs e Do not open battery compartment to prevent battery explosion acid splashing severe damage to eyes or skin e Do not open motor compartment Keep clear from moving rotating wheels sheaves etc or lifting parts e Never carry more passengers than number allowed for this vehicle Wait until all occupants are seated and holding on before moving Always keep all body parts inside vehicle Keep both hands on steering wheel e Do not exceed the vehicle cargo load capacity and gross trailing weight capacity rated for flat hard even surface Different operating conditions such as loose terrain or ramps reduce vehicle capacity e Avoid loose unbalanced or top heavy loads to keep a good stability and prevent overturn Do not load cargo that can fall off the vehicle Do not carry cargo that is longer wider or higher than this vehicle e Always depress slowly the accelerator for smooth acceleration Avoid stunt driving or horseplay e Avoid sharp turns always slow down before turning to prevent vehicle overturn or trailer jack knife Vehicle is
40. sorption or constant voltage phase the last 20 of charge is then returned to the battery The charging could be terminated at this point if the vehicle requires immediate usage however it is highly recommended to wait until 10096 charge indication is given to ensure maximum battery capacity and life A low current finish charge phase is next applied to return and maintain maximum battery capacity Models 912 xx0x will flash the 100 LED When Models 912 xx0x 10096 LED or Models 912 xx1x single LED is continuously GREEN the batteries are completely charged The charger may now be unplugged from AC power always pull on plug and not cord to reduce risk of damage to the cord If left plugged in the charger will automatically restart a complete charge cycle if the battery pack voltage drops below a minimum voltage or 30 days has elapsed If a fault occurred anytime during charging a fault indication is given by flashing RED with a code corresponding to the error There are several possible conditions that generate errors Sorne errors are serious and require human intervention to first resolve the problem and then to reset the charger by interrupting AC power for at least 15 seconds Others may be simply transient and will automatically recover when the fault condition is eliminated To indicate which error occurred a fault indication will flash RED a number of times pause and then repeat 1 FLASH Battery Voltage High auto recover 2 FLAS
41. t voltage with battery remaining in vehicle 2 09V cell reset voltage after battery has been disconnected To maintain a good battery performance it is recommended to limit the discharging to 80 of the battery capacity The recommended setting for 6V batteries 1s F and the recommended setting for an industrial battery is K An internal relay can prevent overdischarging and damaging the batteries The relay can be wired to cut off the reverse direction or energize an N C relay and alarm Turning off and on the vehicle will override the protection for 30 sec The current status remaining operating hours before maintenance of the service down counter is indicated for a period of 5 seconds after the key switch 1s turned on When it 15 down to the display flashes After the maintenance reset the counter depress the button on the rear The service counter is factory programmable only 24V UNIT 2469026 36V UNIT 3069038 48V UNIT 4869037 2 Orange key switch 3 Relay 4 Relay 5 Black battery 6 Blue hour counter 8 White battery 43
42. the motor contactors etc are tight When checking the controller bus bar connections for tightness 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 com pletely 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 mount ing it in a different location or by installing a protective cover Damaged seals can lead to faulty operation We strongly recommend replacing controllers that have faulty seals Curtis PMC 1204 1205 Manual gt 24 22 Fig 18 Adjustment pots MAINTENANCE amp ADJUSTMENT Adjustment On some models the plug braking current and acceleration rate settings are adjustable On these adjustable controllers the adjustment pots are located as shown in Figure 18 PLUG CURRENT ADJUST ACCELE
43. thorized persons only Read operator s instructions in owner s manual prior to driving General security warning label Operation of this vehicle is restricted to authorized persons only Read operator s instructions In owner 5 manual prior to driving Do not operate on roads public streets and unauthorized areas Never open battery compartment Never open motor compartment Warn people to stay away from wheels and moving or lifting parts Never exceed specified max speed cargo or passenger capacity Drive slowly on ramps in turns in reverse Avoid loose cargo Before turning on key switch and while moving be sure that occupants remain seated with seat belt buckled if applicable occupants keep all their body parts inside vehicle occupants keep holding on hand rails wheel chair if applicable is secured with tie down straps trailer attachment if applicable is secured with two chains Before leaving this vehicle park on a flat surface set to neutral set the parking brake turn off all switches and remove the key Respectively key switch markings forward reverse selector markings and light switch marking IC 10 Maintenance PERIODIC MAINTENANCE CHECKLIST WARNING Maintenance operations must be made be 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

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