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MANUAL

MultiMode™

MOTOR CONTROLLER

© 2001 CURTIS INSTRUMENTS, INC.

DESIGN OF CURTIS PMC 1200 SERIES
CONTROLLERS PROTECTED BY U.S.
PATENT NO. 4626750.

12 4 4

MODEL

1244 Manual, p/n 16958

Rev. B: January 2001

CURTIS PMC

235 East Airway Boulevard
Livermore, California 94568 USA
Tel: 925-961-1088
Fax: 925-961-1099
www.curtisinst.com

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Summary of Contents for T-224

Page 1: ...T 224 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1028579 UP Printed in Canada ...

Page 2: ...icle 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 o...

Page 3: ...LLER 20 WIRING STANDARD CONFIGURATION 23 DIAGNOSTICS AND TROUBLESHOOTING 24 TROUBLESHOOTING CHART 25 LED DIAGNOSTICS 26 PROGRAMMING PARAMETERS T 224 224D 27 SPARE PARTS 28 BODY 29 FORD F 150 DIFFERENTIAL 30 DIFFERENTIAL 32 BRAKE CONTROLS DEADMAN SEAT BRAKE 34 STEERING WHEEL AND FRONT AXLE 35 TILT TEL STEERING WHEEL AND FRONT AXLE 36 MOTOR AND DRIVE 37 ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT 38 ACCES...

Page 4: ...Instructions INSTRUCTIONS 4 ...

Page 5: ...ing conditions such as loose terrain or ramps reduce vehicle capacity 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 Always depress slowly the accelerator for smooth acceleration Avoid stunt driving or horseplay Avoid sharp turns always slow d...

Page 6: ...Maintenance MAINTENANCE 6 ...

Page 7: ...ols 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 dis...

Page 8: ...cted 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 is found and part of the text can t be read 8 ...

Page 9: ...ehicle 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 General security warning label Respectively key switch markings forward reverse selector markings and light switch marking 9 ...

Page 10: ...stilled water to cover plates Fill to recommended level after batteries have been fully charged X WARNING DECALS MARKINGS X EE Rated CABLE PROTECTORS SEALED MOTOR SEALED CONTROL BOX X MASTER CYLINDER FLUID DOT 3 X BRAKE PEDAL TRAVEL 2 50 mm maximum travel X STEERING FOR PLAY X PARKING BRAKE LEVER requires 10 lbs 5 kg force to apply X BELTS AND PULLEYS 10 lbs 5kg force for 1 8 3mm deflexion pulleys...

Page 11: ...he on off solenoid when the accelerator is released turn the adjusting screw shown on figure below to adjust the micro switch height POT Remove the terminals 2 and 3 on PMC to measure resistance signal When the micro switch is activated the signal must be less than 50 ohms When the front portion of the pedal is fully depressed the signal must be more than 4600 ohms To modify the resistance turn th...

Page 12: ...l 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 TENSIONING Check the force F required to provide a deflection of 1 8 in If the measured force is less than 15 lbs then lengthen centre distance C 12 ...

Page 13: ...soft or spongy air may have entered the hydraulic system and the brake system has to be bled 1 fill the master cylinder with brake fluid DOT 3 2 bleed front callipers one at a time by having someone applying a steady pressure on the brake pedal and close the bleeder before allowing the brake pedal to return to up position 3 fill the master cylinder with brake fluid DOT 3 4 bleed rear wheel brakes ...

Page 14: ...e push rod until a 1 8 inch 3mm gap remains between the pivot and the spring rods see figure A 3 Tighten the jam nut SPRING ADJUSTMENT Tighten the spring adjustment rods until they exceed the bracket by two inchs 50 mm as shown on figure B BRAKE PADS ADJUSTMENT 1 Slide the seat fully rearward 2 Unscrew the jam nut on the brake cable adjustment bolt on the outer brake pad 3 Unscrew the adjustment b...

Page 15: ... 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 re...

Page 16: ...arger connected for more than 20 hours FREQUENCY OF CHARGE When a battery is discharged to its 20 state of charge it is best to charge immediately Batteries require a low current equalization charge min 4 hours at least every week to equalize battery cells improve battery performance and life in number of cycles Never leave a charger connected for more than 20 hours STORAGE Keep the battery from g...

Page 17: ...ltage 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 ac...

Page 18: ...stance 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 is not constant maximum speed is erratic sudden stop after a bump or shock erratic starts requiring several pedal cycles A bad F R contactor is also a probable cause of the followi...

Page 19: ...k 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 th...

Page 20: ...Curtis Speed Controller CURTIS SPEED CONTROLLER 20 ...

Page 21: ... DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 12 4 4 M O D E L 1244 Manual p n 16958 Rev B January 2001 CURTIS PMC 235 East Airway Boulevard Livermore California 94568 USA Tel 925 961 1088 Fax 925 961 1099 www curtisinst com 21 ...

Page 22: ... KISCO NEW YORK 10549 USA 914 666 2971 FAX 914 666 2188 CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE CALIFORNIA 94550 USA 925 961 1088 FAX 925 961 1099 ADDITIONAL OFFICES located in Bulgaria China England France Germany India Italy Japan Netherlands Puerto Rico Russia Sweden and Switzerland www curtisinst com 22 ...

Page 23: ...n going to the controller s B bus bar and the armature s A2 connection going to the controller s M bus bar The motor s ﬁeld connections F1 and F2 to the controller are less obvious The direction of vehicle travel with the forward direction selected will depend on Fig 3 Standard wiring configuration Curtis PMC 1244 controller B B M F2 F1 INTERLOCK 5kΩ 0 THROTTLE TYPICAL FORWARD MAIN CONTACTOR COIL ...

Page 24: ...r maintenance The following 4 step process is recommended for diagnosing and trouble shooting an inoperative vehicle 1 visually inspect the vehicle for obvious problems 2 diagnose the problem using the programmer 3 test the circuitry with the programmer and 4 correct the problem Repeat the last three steps as necessary until the vehicle is operational Example A vehicle that does not operate in for...

Page 25: ...NG CHECK 1 emergency reverse wiring fault 1 Emergency reverse wire open 2 Emergency reverse check wire open 3 1 CONT DRVR OC 1 cont driver output overcurrent 1 Contactor coil shorted 3 2 MA I N CONT WELDED 1 welded main contactor 1 Main contactor stuck closed 2 Main contactor driver shorted 3 3 PREC HARGE FAUL T 1 internal voltage too low at startup 1 Controller defective 2 External short or leaka...

Page 26: ...Table 6 STATUS LED FAULT CODES LED CODES EXPLANATION LED off no power or defective controller solid on controller or microprocessor fault 0 1 controller operational no faults 1 1 not used 1 2 hardware failsafe fault 1 3 M current sensor or motor fault 1 4 not used 2 1 throttle fault 2 2 static return to off SRO fault 2 3 high pedal disable HPD fault 2 4 emergency reverse circuit check fault 3 1 co...

Page 27: ...T BRAKING AS OF BRAKE C L 50 LOAD COMP LOAD COMPENSATION 0 TO 25 0 M1 ACCEL RATE MODE 1 ACCELERATION RATE IN SEC 4 HPD HIGH PEDAL DISABLE HPD TYPE 1 M2 ACCEL RATE MODE 2 ACCELERATION RATE IN SEC 4 SRO STATIC RETURN TO OFF SRO TYPE 1 M3 ACCEL RATE MODE 3 ACCELERATION RATE IN SEC 4 SEQUENCING DLY SEQUENCING DELAY IN SEC 1 M4 ACCEL RATE MODE 4 ACCELERATION RATE IN SEC 4 MAIN CONT INTR MAIN CONTACTOR ...

Page 28: ...Spare Parts SPARE PARTS 28 ...

Page 29: ...1 GS 12 GRAMMER SEAT 2205002 GS 12 GRAMMER SEAT SWITCH 2305002 DELUXE GRAMMER SEAT 3 2807001 5 BOLT SOLID BLACK RUBBER WHEEL 2207004 5 BOLT 16 O D N M MOLD ON WHEEL 4 2200018 ROLLER 2200019 SHAFT 2200010 BEARING 5 2205003 LATCH 6 2301001 BUMPER 7 2500250002 DASH PLATE 29 ...

Page 30: ...Spare Parts FORD F 150 DIFFERENTIAL 30 ...

Page 31: ...Spare Parts 31 ...

Page 32: ...Spare Parts DIFFERENTIAL 32 ...

Page 33: ...BEARING 18 2235008 HOUSING 19 2320006 SPACER 20 242063 BREATHER 21 242064 SPACER 22 242065 TAPERED BEARING 23 242066 SHIM 24 242067 GEAR KIT 27 242069 SHIM 28 242070 TAPERED BEARING 29 242071 CASE 30 242072 WASHER 31 242073 GEAR KIT 32 242074 WASHER 33 3620027 GEAR KIT 34 242076 SCREW 35 3620006 SHAFT 36 242078 CAP 37 BOLT 38 242079 DRAIN PLUG 39 242080 DIFFERENTIAL COVER 42 2420019 BOLT 43 481432...

Page 34: ... HOLDER 8 242817 LUBRICATION FITTING 28 2316013 ADJUSTMENT ROD 9 CLEVIS PIN 3 8 X 1 29 2290002 ROD END 1 2 10 122813 YOKE 31 362831 CABLE 11 362805 MASTER CYLINDER 33 362833 CABLE STOP 12 BOLT 3 8 NC X 3 34 2316005 HANDBRAKE PAD 13 2216007 ROD 15 35 3616014 HANDBRAKE PAD 2216021 ROD 17 36 3616015 SPRING 20 lbs 16 2216019 SEAT BRAKE PLATE 43 2216011 CABLE ADJUSTMENT 17 2216018 SEAT BRAKE PLATE 44 2...

Page 35: ...WASHER 3 8 22 2235003 OIL SEAT 4 481454 PIN 23 2235004 TAPER BEARING 5 231401 FORK 24 2235002 HUB 6 201423 BALL BEARING 25 241005 WHEEL NUT 7 BOLT 1 2 NF X 1 1 2 26 241006 BUSHING 8 LOCKWASHER 1 2 27 NUT 1 NF 9 481453 COVER 28 231403 TUBE 10 481452 NUT 3 4 NF 29 231404 UNIVERSAL JOINT 11 231402 SHAFT 30 231405 PIVOT 12 3030020 BUSHING 33 1022002 CHAIN 13 3030021 OIL SEAL 35 ...

Page 36: ...RING 24 2235002 HUB 7 BOLT 1 2 NF X 1 1 2 25 BOLT 1 2 NF 8 LOCKWASHER 1 2 26 241006 BUSHING 9 2330014 HORN BUTTON 27 NUT 1 NF 10 2230014 TILT TEL COLUMN 29 231404 UNIVERSAL JOINT 11 2230020 SHAFT 30 231405 PIVOT 12 2230018 NYLON COUPLER 33 1022002 CHAIN 13 2230019 SHAFT 34 2230022 STOPPER 14 2330015 UNIVERSAL JOINT 35 366212 SWITCH 15 2230015 SUPPORT TILT TEL COLUMN 36 800TXA CONTACT BLOC 16 22300...

Page 37: ...HER PACK 484006 BELT TENSIONER SHORT 2452003 15 WAVY WASHER 484013 7 PIVOT 2452002 19 HEADBAND 484015 EE HEADBAND KIT A91 107A SPECIFIC REF DESCRIPTION A89 B98 A00 D00 SEPEX DC3 SEPEX DANA DRIVE MOTOR ASS Y 484000 204050 2950002 2450003 3112210001 3122230001 13 BRUSH SPRING 484010 484010 2450006 2450006 2450006 2450006 14 BRUSH PLATE 484011 484011 2450007 2450007 2450007 2450007 16 LEAD ASSY 48401...

Page 38: ...Spare Parts ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT DIAGRAMME ÉLECTRIQUE CIRCUIT PRINCIPAL SEPEX 38 ...

Page 39: ...Spare Parts ACCESSORIES NO DC DC ONVERTER ACCESSOIRES SANS CONVERTISSEUR DC DC 39 ...

Page 40: ...62008 1 S1 KEY SWITCH 246205 1 S3 SEAT SWITCH MICRO SWITCH 31091000002 1 SEAT SWITCH SEAT MOUNTED 366216 1 S7 F R SELECTOR COLUMN 436212 1 F R SELECTOR TILT TEL COLUMN 366212 1 F R SELECTOR ROCKER TYPE 266211 1 S8 LIGHT SWITCH ROCKER TYPE 1269004 1 S10 HORN BUTTON COLUMN MOUNT 1 HORN BUTTON TILT TEL COLUMN 2330014 1 HORN BUTTON FLOOR MOUNT 246220 1 S12 HYDRAULIC BRAKE LIGHT SWITCH 3669004 1 S15 EM...

Page 41: ...amp Grommet 3269001 12V 3669012 24V 3669012A Clear lamp 12V 3069012 Bulb 12V 1269008 Pedestral head lamp 12V 2569001 Bulb 12V 2569001B Bulb 24V 4469001 Headlight Left 3111480003 Right 3111480004 Bulb H L 3111480006 Bulb Turn 3111480008 Bulb Mark 3111480007 Headlight Left 3111480003 Right 3111480004 Bulb H L 3117480001 Bulb Turn 3117480003 Bulb Mark 3117480002 Turn signal switch 246050 Analog Voltm...

Page 42: ...211 Wiper arm 2800000001 Wiper blade 14 Blade 2800000002 18 Blade 2800000003 Pantograph wiper arm 246233A Pantograph wiper blade 246233 Cab heater 12V 3103300001 36V 3669008 48V 4869020 12V Dome light 3669006 12V Fan 3669013 Headlamp 12V 3111250002 Headlamp 12V 3111300001 Bulb 12V 3111300002 Red Pilot light 12V 246212 Bulb 12V 246212B 42 ...

Page 43: ...Spare Parts CONVERTER INSTALLATION 43 ...

Page 44: ...od battery performance it is recommended to limit the discharging to 80 of the battery capacity The recommended setting for 6V batteries is F and the recommended setting for an industrial battery is K An internal relay can prevent overdischarging and damaging the batteries The relay can be wired to cut off the reverse direction or energize an N C relay and alarm Turning off and on the vehicle will...

Page 45: ...Addendum ADDENDUM 45 ...

Page 46: ...FOOT PEDAL PART NO DESCRIPTION 3062001C ACCELERATOR CURTIS 367008 POTENTIOMETER 2262004C SPRING 2262001C MICRO SWITCH 2262003C LEVER 3662002 CABLE PROTECTOR RESP CLAUDE L MODEL E T 224 236 248 NO 235A224001 SER TO À 46 ...

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