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Motrec T-448HD, Operator And Maintenance Manual

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Motrec T-448HD Operator And Maintenance Manual Download Page 23

MANUAL

© 2003 CURTIS INSTRUMENTS, INC.

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

1214-8 / 1215-8 / 1219-8 Manual

p/n 16369, Rev. C: April 2003

CURTIS INSTRUMENTS, INC.

200 Kisco Avenue
Mount Kisco, NY 10509 USA
Tel: 914-666-2971
Fax: 914-666-2188
www.curtisinst.com

MultiMode™

MOTOR CONTROLLERS

1214-8
1215-8
1219-8

- 23 -

Summary of Contents for T-448HD

Page 1: ...T 448HD OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1006000 UP Printed in Canada...

Page 2: ...ly 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...

Page 3: ...IES SPEED CONTROLLER 22 ELECTRICAL DIAGRAM 24 CURTIS SPEED CONTROLLER 26 WIRING STANDARD CONFIGURATION 29 DIAGNOSTICS AND TROUBLESHOOTING 30 TROUBLESHOOTING CHART 31 LED DIAGNOSTICS 32 PROGRAMMING PAR...

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

Page 5: ...ting 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 v...

Page 6: ...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 wil...

Page 7: ...Maintenance 7 MAINTENANCE...

Page 8: ...aminated 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 t...

Page 9: ...ected 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...

Page 10: ...he vehicle It is of prior importance that theses decals markings remain unaltered and readable Else the sticker or the part bearing the marking has to be replaced Dashboard security warning label Gene...

Page 11: ...CK FILL BATTERIES add distilled water to cover plates Fill to recommended level after batteries have been fully charged X MASTER CYLINDER FLUID DOT 3 X BRAKE PEDAL TRAVEL 2 50 mm maximum travel X STEE...

Page 12: ...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 sig...

Page 13: ...til 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 T...

Page 14: ...s 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...

Page 15: ...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 tire...

Page 16: ...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 are...

Page 17: ...charger connected for more than 20 hours FREQUENCY OF CHARGE When a battery is discharged to its 20 state of charge it is best to charge immediately Batteries require a low current equalization charge...

Page 18: ...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 po...

Page 19: ...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 t...

Page 20: ...sistance 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 f...

Page 21: ...eck 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...

Page 22: ...Series Speed Controller 22 SERIES SPEED CONTROLLER...

Page 23: ...NTROLLERS PROTECTED BY U S PATENT NO 4626750 1214 8 1215 8 1219 8 Manual p n 16369 Rev C April 2003 CURTIS INSTRUMENTS INC 200 Kisco Avenue Mount Kisco NY 10509 USA Tel 914 666 2971 Fax 914 666 2188 w...

Page 24: ...Series Speed Controller 24 ELECTRICAL DIAGRAM DIAGRAMME LECTRIQUE...

Page 25: ...Series Speed Controller 25...

Page 26: ...Curtis Speed Controller 26 CURTIS SPEED CONTROLLER...

Page 27: ...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 9456...

Page 28: ...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 En...

Page 29: ...on 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 eld connections F1 and F2 to the controller are less obvious The direction of ve...

Page 30: ...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...

Page 31: ...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 WELD...

Page 32: ...able 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...

Page 33: ...RK MODE 4 THROT BRAKING AS OF BRAKE C L 100 LOAD COMP LOAD COMPENSATION 0 TO 25 0 M1 ACCEL RATE MODE 1 ACCELERATION RATE IN SEC 4 HPD HIGH PEDAL DISABLE HPD TYPE 2 M2 ACCEL RATE MODE 2 ACCELERATION RA...

Page 34: ...Spare Parts 34 SPARE PARTS...

Page 35: ...DJUSTER NOT ILLUSTRATED 2 2384300009 BACKREST FRAME 3 4400007 BATTERY COVER 4 2330448002 MOTOR COVER 5 2339448004 CONTROLS COVER 6 300022 5 7X8 LRD WHEEL 300024H 5 7X8 NSH TITAN PREMIUM WHEEL 22233600...

Page 36: ...Spare Parts 36 FORD F 150 DIFFERENTIAL...

Page 37: ...Spare Parts 37...

Page 38: ...bber pad 1 18 Clevis pin 5 16 x 1 1 2 1 6 2131360002 Lever 1 19 2139240002 Handbrake lever 1 6 2131360012 Lever 1 20 2129000003 Handbrake cable 1 7 2133280001 Push rod Master cylinder 1 21 2129000001...

Page 39: ...Spare Parts 39 FRONT AXLE SUSPENSION STEERING DISC BRAKES...

Page 40: ...LEFT AXLE 45 481470 LOCK WASHER 13 481464 AXLE BEAM 46 481471 NUT 14 2205250001 KING PIN 47 2814003 PADS 15 2910300001 NUT 3 4 NF 48 481474 STEERING SUPPORT 16 2103250001 THRUST BEARING 49 2910300002...

Page 41: ...2 484002 DRIVE ENDHEAD 13 484013 WAVY WASHER 3 484003 BEARING 14 2450009 COMMUTATOR ENDHEAD 4 484004 SNAP RING 15 484015 HEAD BAND ASS 5 484016 ARMATURE FAN 16 2450004 ARMATURE ASS 6 484006 NUT WASHER...

Page 42: ...PENSION REF PART NO DESCRIPTION 1 2192320001 LEAF SPRING 2 2185280001 MOUNTING LEAF SPRING 3 3640004 U BOLT 3 I D 4 5040004 U BOLT 4 I D 5 2183240002 BUSHING 6 2182320002 BAR 7 242057 BOLT 8 218244800...

Page 43: ...Spare Parts 43 ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT...

Page 44: ...Spare Parts 44 ACCESSORIES DC DC CONVERTER ACCESSOIRES CONVERTISSEUR DC DC...

Page 45: ...Spare Parts 45 OPTIONS...

Page 46: ...OTOR 1 M4 CAB HEATER 48V 4869020 1 P1 INDICATOR BDI HOUR METER 1 R1 ACCELERATOR 367001 1 MICROSWITCH 367002 1 POTENTIOMETER 367003 1 PLASTIC GEAR 367015 1 S1 KEY SWITCH 246205 1 S2 SEAT SWITCH 247002...

Page 47: ...lamp 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 Bul...

Page 48: ...86211 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 lig...

Page 49: ...Spare Parts 49 CONVERTER INSTALLATION...

Page 50: ...good battery performance it is recommended to limit the discharging to 80 of the battery capacity The recommended setting for 6V batteries is F and the recommended setting for an industrial battery is...

Page 51: ...PART NO DESCRIPTION 1 3062001C ACCELERATOR CURTIS 2 367008 POTENTIOMETER 3 2262004C SPRING 4 2262001C MICRO SWITCH 5 2262003C LEVER 6 3662002 CABLE PROTECTOR RESP CLAUDE L MODEL E E 320 360 480 500 N...

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