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TUG MZ Operation Maintenance & Parts Manual

TUG MZ Operation Maintenance & Parts Manual

Tow tractor

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MODEL MZ

TOW TRACTOR

OPERATION, MAINTENANCE

& PARTS MANUAL

CD373

Table of Contents

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Table of Contents

Troubleshooting

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Summary of Contents for TUG MZ

Page 1 MODEL MZ TOW TRACTOR OPERATION, MAINTENANCE & PARTS MANUAL CD373...
Page 2 TUG. NOTE: The information contained in this document is intended to be accurate and up to date at the time of original issue. TUG reserves the Note right to update the information in this document, without warning, as deemed prudent or necessary by TUG.
Page 3 State: Zip Code: REVISION DATA Check each revision received, and insert the revised and supplementary pages in your manual. TUG assumes no liability for personal injury or equipment failure due to any operation performed without heed to manual revisions. Date of original publication: September 2008...
Page 4 Introduction MZ Tow Tractor LIST OF EFFECTIVE PAGES Chapter-Section Page Revision Chapter-Section Page Revision INTRO- Rev 3 SAFETY- Orig INTRO- Orig SAFETY- Orig INTRO- Rev 3 INTRO- Rev 3 1-TOC- Orig INTRO- Rev 3 1-TOC- Orig INTRO- Rev 3 INTRO-...
Page 5 MZ Tow Tractor Introduction Chapter-Section Page Revision Chapter-Section Page Revision 2-TOC- Orig 3-TOC- Orig 2-TOC- Orig 3-TOC- Orig 2-1- Rev 3 3-1- Orig 2-1- Rev 3 3-1- Orig 2-1- Orig 2-1- Rev 3 3-2- Orig 2-1- Rev 3 3-2- Orig...
Page 6 Introduction MZ Tow Tractor Chapter-Section Page Revision Chapter-Section Page Revision 4-TOC- Rev 3 4-2- Rev 3 4-TOC- Rev 3 4-2- Rev 3 4-2- Rev 3 4-1- Orig 4-2- Rev 3 4-1- Rev 3 4-2- Rev 3 4-1- Rev 3 4-2-...
Page 7 MZ Tow Tractor Introduction Chapter-Section Page Revision Chapter-Section Page Revision 4-2- Rev 3 5-TOC- Orig 4-2- Rev 3 5-TOC- Orig 4-3- Rev 3 5-1- Orig 4-3- Rev 3 5-1- Orig 4-3- Rev 3 4-3- Rev 3 5-2- Orig 4-3- Rev 3...
Page 8 Introduction MZ Tow Tractor MANUAL TABLE OF CONTENTS INTRODUCTION Record of Revisions ....................... INTRO-iii List of Effective Pages......................INTRO-iv Manual Table of Contents ..................... INTRO-viii Copyright Notice ........................INTRO-xvi Introduction .......................... INTRO-xvii Unit Identification ......................... INTRO-xvii Technical Assistance ......................INTRO-xviii Warranty Policy Statement ....................INTRO-xix How to Use This Manual .....................
Page 9 MZ Tow Tractor Introduction Hydraulic Steering System ................ 1-1-3 Brakes ...................... 1-1-3 Chassis ....................1-1-3 SECTION 2: OPERATION ......................1-2-1 Introduction ......................1-2-1 Controls and Indicators ..................1-2-2 Multifunction Display ................. 1-2-2 Master (“Ignition”) Switch ................1-2-3 Headlight Switch ..................1-2-3 Maneuvering Controls ...................
Page 10 Introduction MZ Tow Tractor Brakes ...................... 1-3-1 Drive Axle ....................1-3-1 Steering ..................... 1-3-2 Gear Ratio ....................1-3-2 Safety Features ....................1-3-2 SECTION 4: SHIPPING ......................1-4-1 Introduction ......................1-4-1 Preparation for Shipment ..................1-4-1 Receiving ......................1-4-1 SECTION 5: STORAGE ......................1-5-1 Introduction ......................
Page 11 Figure 1-7. Electrical Schematic (Sheet 5 of 6) ............ 2-2-9 Figure 1-8. Electrical Schematic (Sheet 6 of 6) ..........2-2-10 Figure 1-9. MZ Quick Charge Option (Sheet 1 of 3) ........... 2-2-11 Figure 1-10. MZ Quick Charge Option (Sheet 2 of 3) ......... 2-2-12 Figure 1-11.
Page 12 Introduction MZ Tow Tractor SECTION 3: REMOVAL / INSTALLATION ................2-3-1 Introduction ......................2-3-1 Capacitor Discharge Procedure ............... 2-3-1 Removal / Installation .................... 2-3-2 Operator/Passenger Seat ................. 2-3-2 Drive Direction Selector ................2-3-2 Main Power ("Ignition") Switch ..............2-3-3 Master Cylinder ..................2-3-3 Steering Wheel ..................
Page 13 MZ Tow Tractor Introduction Pump Installation ....................3-3-7 SECTION 4: MASTER CYLINDER DISASSEMBLY AND ASSEMBLY ........3-4-1 Master Cylinder Removal ..................3-4-1 Master Cylinder Disassembly ................3-4-1 Inspection and Repair ................... 3-4-1 Master Cylinder Re-Assembly ................3-4-2 Bleeding The Master Cylinder ................3-4-2 Master Cylinder Installation ...................
Page 14 Introduction MZ Tow Tractor CHAPTER 4: ILLUSTRATED PARTS LIST SECTION 1: DESCRIPTION ..................... 4-1-1 Introduction ......................4-1-1 Using the Illustrated Parts List ................4-1-2 Figure and Index Number ................4-1-2 Part Number ..................... 4-1-3 Description and Quantity ................4-1-3 Effectivity....................4-1-4 Ordering Spare Parts ....................
Page 15 MZ Tow Tractor Introduction Figure 2-25. Rear Suspension ................4-2-54 Figure 2-26. Wheels and Tires ................4-2-56 Figure 2-27. Park Brake Assembly ..............4-2-58 Figure 2-28. Park Brake Cable Assembly ............4-2-60 Figure 2-29. Brake Pedal Assembly ..............4-2-62 Figure 2-30. Front Brake Lines ................4-2-64 Figure 2-31.
Page 16 TUG. Any attempt by any person other than an authorized agent of TUG to alter the contents of this manual in any way shall be construed as copyright infringement, punishable by all applicable laws.
Page 17 UNIT IDENTIFICATION To aid the technician in repair or service work on this unit, a TUG identification plate is located on the operator's compartment of the unit. TUG TECHNOLOGIES CORPORATION...
Page 18 Introduction MZ Tow Tractor TECHNICAL ASSISTANCE Direct any questions concerning the operation of the MZ Tow Tractor to: TUG Technologies Corporation P.O. Box 3028 Kennesaw, GA 30156 Domestic: 1-800-989-8499 International: (770) 422-8021 Fax: (770) 422-8730 All information in this manual is based on the latest production information available at the time of publication.
Page 19 - all aspects of the products themselves and the service that backs them up. This manual is directed to TUG Technologies’ distributors and customers of TUG Equipment. It should be used to implement the Warranty Program at every level.
Page 20 Any repair made to a product that has been misused or mistreated, or upon which a conversion, modification or installation of a non-TUG part has been made so as to affect the performance, reliability or stability of a part. Any failure to a TUG-supplied part resulting from such action is not covered by the warranty.
Page 21 • Repair techniques beyond the appropriate shop manual limits. • Labor performed by anyone other than an authorized TUG technician without prior approval, unless the situation is an emergency. • Use of any other than genuine TUG parts, unless used in an emergency.
Page 22 Return Parts: Not all failed parts need to be returned to TUG Technologies. If parts are to be returned, an RGA tag will be sent with the replacement warranty parts. The tag must be filled out completely and attached to the return part(s).
Page 23 All the expenses related to a warranty claim will be invoiced to the buyer until TUG Technologies has evaluated the claim. Whatever the circumstances, the buyer should not refuse or delay the payment. If the evaluation concludes to TUG’s full responsibility, a credit will be issued in the favor of the buyer.
Page 24 Introduction MZ Tow Tractor Table 1. Tow Tractor Warranty Labor Flat Rate Guide MT12 Body R&R Hood R&R Radiator Shroud Repaint 10.0 Repaint Cab Brakes R&R Master Cyl and Bleed R&R Brake Booster Adjust Brake Booster R&R Hard Brake Lines and Bleed R&R Master Cylinder Cover Gasket...
Page 25 MZ Tow Tractor Introduction Table 1. Tow Tractor Warranty Labor Flat Rate Guide (Cont'd) MT12 Cooling System R&R Fan R&R Radiator & Transfer Shroud R&R Top or Bottom Hose R&R Heater Hose R&R Water Pump R&R Thermostat Controls R&R Shifter R&R Shifter Cable and Adjust...
Page 26 Introduction MZ Tow Tractor Table 1. Tow Tractor Warranty Labor Flat Rate Guide (Cont'd) MT12 Electrical Troubleshoot Short or No Power R&R Coolant Temp Sensor R&R Coolant Gauge R&R Hour Meter R&R Ammeter R&R Electric Fuel Gauge R&R Electric Fuel Sender R&R Kysor Coolant Temperature Sensor...
Page 27 MZ Tow Tractor Introduction Table 1. Tow Tractor Warranty Labor Flat Rate Guide (Cont'd) MT12 Front Suspension and Steering R&R Front Spring R&R Front Axle and Transfer Springs R&R Tie Rod End and Adjust Toe In R&R King Pin R&R Drag Link R&R Pitman Arm - Gas...
Page 28 Introduction MZ Tow Tractor Table 1. Tow Tractor Warranty Labor Flat Rate Guide (Cont'd) MT12 Transmission R&R Transmission R&R Transmission Front Oil Seal Gas R&R Transmission Rear Oil Seal R&R Modulator Valve R&R Modulator Cable R&R Pan Gasket and Refill R&R Shifter Interlock Solenoid...
Page 29 Introduction HOW TO USE THIS MANUAL Important Notice: TUG recommends that the vehicle operator thoroughly study the contents of this handbook before attempting to operate the vehicle. This handbook is divided into five chapters. Refer to the Table of Contents at the front of this manual for details of chapter content.
Page 30 Introduction MZ Tow Tractor (This page intentionally left blank.) INTRO-xxx CD373 Orig...
Page 31 SAFETY GENERAL Operator and mechanic safety is so important at TUG that the initial design and build of every product undergoes a thorough review of all the components to produce the safest equipment available today. To reinforce this action, this section of the manual is devoted to safety and must be read by every operator and mechanic that may be involved with this equipment.
Page 32 Safety MZ Tow Tractor Low operator seating for easy mounting/dismounting with adjustable seat for proper leg room. Seat belts. Nonslip covering on floor boards. Nonslip "Morton Cast" surface on brake pedal. Power steering. Front wheel dry-disc brakes; rear wheel wet-disc brakes.
Page 33 MZ Tow Tractor Safety Always wear suitable footwear when operating this equipment. Always bring the unit to a complete stop, place the direction control in neutral, and set the park brake before dismounting. Always bring the unit to a complete stop before shifting from forward to reverse or from reverse to forward.
Page 34 Safety MZ Tow Tractor Do not drive across any slope. Always leave room when stopping and starting on hills to allow for slight roll back downhill. Never engage in “horseplay” with the tractor. Always exercise good common sense, stay alert and be aware of what is happening around the tractor at all times.
Page 35 MZ Tow Tractor Safety Check brakes and fill the master cylinder with DOT 3 brake fluid. Check all lights. Check horn operation. Do not disconnect or otherwise disable the safety seat switch. Check tire and wheel condition along with proper inflation pressures. Unless beads are seated when mounting tires, over-inflation can result in explosion.
Page 36 Safety MZ Tow Tractor Always deflate a tire and wheel assembly prior to removing it for servicing or dismounting. Do not use wheels or wheel components that are cracked, bent pitted or corroded. Ensure that all wheel components are of the same type and size, and that wheel size and tire size match.
Page 37 MZ Tow Tractor Safety WARNING STATEMENTS WARNING: ALWAYS USE CAUTION WHEN INSPECTING EQUIPMENT. BEGIN ONLY WHEN THE EQUIPMENT IS SHUT DOWN, ISOLATED, AND TAGGED “OUT OF SERVICE.” ANY ACCIDENTAL OR POORLY-TIMED OPERATION CAN CAUSE SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT.
Page 38 MUST BE TIGHTENED ONLY UNDER PRESSURELESS CONDITIONS. CAUTIONARY STATEMENTS CAUTION: FOR YOUR OWN PROTECTION, DO NOT USE SUBSTITUTE PARTS WITHOUT THE APPROVAL OF TUG TECHNOLOGIES CORPORATION. CAUTION: WHEN CLEANING, USE ONLY AN APPROVED SOLVENT TO PREVENT DAMAGE AND/OR DETERIORATION TO THE EQUIPMENT.
Page 39: Table Of Contents
Chapter 1 MZ Tow Tractor Table of Contents CHAPTER 1: GENERAL INFORMATION & OPERATING INSTRUCTIONS TABLE OF CONTENTS SECTION 1: DESCRIPTION ..................... 1-1-1 Introduction ......................1-1-1 System Description ....................1-1-2 Components ..................... 1-1-2 Axle Drive System ..................1-1-3 Battery ...................... 1-1-3 Lighting and Horn Systems ...............
Page 40 Chapter 1 Table of Contents MZ Tow Tractor Starting Procedure ....................1-2-8 Operating Characteristics ..................1-2-8 Parking Brake ................... 1-2-8 Power Steering Pump ................1-2-8 Seat Safety Switch..................1-2-9 Shutdown Procedure .................... 1-2-9 Maintenance Towing ..................... 1-2-9 SECTION 3: SPECIFICATIONS ....................1-3-1 General .........................
Page 41: Section 1: Description
An 80-Volt traction battery design has been incorporated into the overall chassis architecture. This design provides ballast for a low center of gravity and drawbar weight, which enables the MZ to have exceptional pulling power. The suspension has been specially designed to provide a smooth ride.
Page 42: System Description
Chapter 1 Section 1 MZ Tow Tractor SYSTEM DESCRIPTION Components The MZ Tow Tractor consists of the following systems/components: • Axle Drive System • Hydraulic Steering System • Battery • Brake System • Lighting and Horn System • Chassis Figure 1-2 provides a functional representation of the tractor's electrical and drive systems.
Page 43: Axle Drive System
MZ Tow Tractor Section 1 Axle Drive System An electric drive system powers the MZ Tow Tractor (refer to Chapter 5 for further details). The electronic drive system consists of the following major components, integrated to function as a single drive system: Transaxle.
Page 44 Chapter 1 Section 1 MZ Tow Tractor (This page intentionally left blank.) 1-1-4 CD373 Orig...
Page 45: Section 2: Operation
SECTION 2: OPERATION INTRODUCTION This section contains instructions for safe and effective operation of the MZ Tow Tractor. A description of each of the vehicle’s operating controls and indicators familiarize the operator with the purpose and function of the controls and indicators. Following the description of the controls and indicators, operating instructions help the operator become familiar with starting, operating, and shutting down the vehicle.
Page 46: Controls And Indicators
20% of their capacity. This way, an operator can treat the “fuel gauge” in the MZ Electric Tow Tractor exactly the same as a fuel gauge in a gas or diesel tractor without worrying about damaging the battery.
Page 47: Master ("Ignition") Switch
Chapter 1 MZ Tow Tractor Section 2 Figure 2-2. Multifunction Display Master (“Ignition”) Switch The ignition switch is the main power switch for all systems. When the switch is ON, power is made available for the throttle, hydraulics, and all related systems. When the switch is OFF, power is not available for any systems, including lights and horn.
Page 48: Maneuvering Controls
Chapter 1 Section 2 MZ Tow Tractor MANEUVERING CONTROLS Maneuvering controls on the MZ include the following: Steering Wheel The hydraulic steering system is powered by an electric hydraulic pump. To turn left, rotate the steering wheel counterclockwise. To turn right, rotate the steering wheel clockwise.
Page 49: Drive Direction Selector
Chapter 1 MZ Tow Tractor Section 2 Drive Direction Selector The drive direction lever controls vehicle travel direction (traction motor rotation) by supplying signals to the inverter control board. To select a vehicle drive direction: Lift upward on selector detent knob.
Page 50: Parking Brake
Battery Assuming a minimum 80% charge, the duration of usable charge of the MZ battery will vary from several hours to perhaps a day or more. Variables that affect length of usable charge include the percentage of initial day’s charge, intensity of use, size and condition of battery, weight of towed loads as well as environmental factors such as ambient temperature.
Page 51: Brakes
Chapter 1 MZ Tow Tractor Section 2 Brakes Check master cylinder fluid level, located behind the console panel to the right of the steering wheel. If low, top off master cylinder reservoir with DOT 3 brake fluid. Service brakes should be tested for pedal firmness and braking effectiveness.
Page 52: Starting Procedure
Chapter 1 Section 2 MZ Tow Tractor STARTING PROCEDURE WARNING: OBSERVE ALL SAFETY PRECAUTIONS DISCUSSED IN THE SAFETY SECTION OF THIS MANUAL. Perform the following procedure to start the vehicle while observing the multifunction display. The vehicle will not respond to the accelerator until the start procedure is successfully completed.
Page 53: Seat Safety Switch
Place the direction control in NEUTRAL and turn the power switch OFF. If needed, plug tractor into battery charger. MAINTENANCE TOWING If it becomes necessary to tow the MZ tow tractor for maintenance or other reasons, the following conditions must be satisfied: The unit must be turned off.
Page 54 Chapter 1 Section 2 MZ Tow Tractor (This page intentionally left blank.) 1-2-10 CD373 Orig...
Page 55: Section 3: Specifications
Chapter 1 MZ Tow Tractor Section 3 SECTION 3: SPECIFICATIONS GENERAL Dimensions Length ......................117 in (2972 mm) Width ......................57 in (1448 mm) Seat Height ....................30 in (762 mm) Steering Wheel Height .................. 49 in (1245 mm) Wheel Base ....................60 in (1524 mm) Ground Clearance ..................
Page 56: Safety Features
Chapter 1 Section 3 MZ Tow Tractor Steering Steering ......................Hydrostatic Gear Ratio Gear Ratio ......................23.9:1 SAFETY FEATURES Master switch - The switch that would normally be used to start a gasoline engine now serves as a main power switch. When the switch is in the OFF position, power to all systems is shut off, thus eliminating the possibility of accidental power loss from headlights or other systems accidently left on.
Page 57: Section 4: Shipping
Secure unit in place using the (2) D-ring locations in the front (Figure 4-1) and either the hitch or single D-ring (if equipped) on the rear of the unit. Front D-Ring Locations Figure 4-1. MZ Tow Tractor (Front View) RECEIVING Before placing the unit into operation, follow the preoperational guidelines included in Chapter 2, Section 1, Part B.
Page 58 Chapter 1 Section 4 MZ Tow Tractor (This page intentionally left blank.) CD373 1-4-2 Orig...
Page 59: Section 5: Storage
Chapter 1 MZ Tow Tractor Section 5 SECTION 5: STORAGE INTRODUCTION Short term storage procedures apply to storage periods between 30 to 90 days, and extended storage procedures for periods greater than 90 days. In either case, store the vehicle in a clean, dry place with protection from temperature extremes and/or high humidity.
Page 60 Chapter 1 Section 5 MZ Tow Tractor Reduce tire pressure to 15 psi and spray with a rubber preservative. Disconnect battery cables and service in accordance with step (g) below. Lubricate vehicle in accordance with instructions in Chapter 2, Section 1, paragraphs D-E.
Page 61: Section 6: Battery Charging
Chapter 1 MZ Tow Tractor Section 6 SECTION 6: BATTERY CHARGING BATTERY CHARGING CYCLES If you are new to the use and maintenance of an electric vehicle, there are some practical aspects of battery charging cycles with which you should become familiar.
Page 62 Chapter 1 Section 6 MZ Tow Tractor If the tractor is available for use on a 24-hour day basis, it may be difficult to find the time to restore the battery charge to it’s highest potential in that upper 20% range. It should be noted that perpetual use of “fast”...
Page 63: Guidelines For Your Charging Regimen
Chapter 1 MZ Tow Tractor Section 6 Guidelines for Your Charging Regimen During quick charges always charge battery to a minimum of 80% of capacity. Never allow battery to become discharged below 20% of capacity. Charge to 100% of capacity whenever possible. Put the battery on an extended or "equalize"...
Page 64: Storage And Cold Weather Considerations
Chapter 1 Section 6 MZ Tow Tractor Make sure the charger is off. Attach charger connector to mating battery connector on the vehicle. Select the equalize charging cycle and charge the battery. Allow the charger to complete the full cycle.
Page 65 Chapter 2 MZ Tow Tractor Contents CHAPTER 2: MAINTENANCE TABLE OF CONTENTS SECTION 1: MAINTENANCE..................... 2-1-1 Introduction ......................2-1-1 General Preparations for Use ................2-1-1 Battery ...................... 2-1-1 Brakes ....................... 2-1-1 Tires ......................2-1-2 Power Steering ..................2-1-2 Periodic Maintenance Schedule ................2-1-2 Daily Check ....................
Page 66 Figure 2-1. Electrical Schematic (Sheet 5 of 6) ............ 2-2-9 Figure 2-1. Electrical Schematic (Sheet 6 of 6) ..........2-2-10 Figure 2-2. MZ Quick Charge Option (Sheet 1 of 3) ........... 2-2-11 Figure 2-2. MZ Quick Charge Option (Sheet 2 of 3) ........... 2-2-12 Figure 2-2.
Page 67: Section 1: Maintenance
GENERAL PREPARATIONS FOR USE Battery Assuming a minimum 80% charge, the duration of usable charge of the MZ battery will vary from several hours to perhaps a day or more. Variables that affect length of usable charge include the percentage of initial day’s charge, intensity of use, size and condition of battery, weight of towed loads as well as environmental factors such as ambient temperature.
Page 68: Tires
Chapter 2 Section 1 MZ Tow Tractor Check park brake. With the main switch in the off position, the park brake should hold the unit in place on a 10% grade. WARNING: DRIVE TRAIN HAS NO “PARK” POSITION AND MUST RELY ON PARK BRAKE TO PREVENT VEHICLE FROM ROLLING.
Page 69: Weekly Or 50-Hour Check
MZ Tow Tractor Section 1 WARNING: DO NOT CHANGE PNEUMATIC TIRE FOR CUSHION TIRE OR VICE VERSA WITHOUT FIRST CONSULTING TUG TECHNOLOGIES CORPORATION. TIRES OF A DIFFERENT TYPE OR MAKE, TREAD OR MATERIAL CAN REDUCE THE LOAD CAPACITY OR AFFECT SAFETY.
Page 70: Two-Week Or 100-Hour Check
Chapter 2 Section 1 MZ Tow Tractor Two-Week or 100-Hour Check WARNING: DRIVE TRAIN HAS NO “PARK” POSITION AND MUST RELY ON PARK BRAKE TO PREVENT VEHICLE FROM ROLLING. ALWAYS MAKE SURE PARK BRAKE IS PROPERLY ADJUSTED BEFORE PUTTING VEHICLE INTO SERVICE.
Page 71: Yearly Or 3000-Hour Check
CAUTION: FAILURE TO FOLLOW THE MAINTENANCE GUIDELINES WRITTEN IN THIS MANUAL WILL VOID BOTH THE TUG AND PRO-MEC WARRANTIES ON THE DRIVE AXLE. Drain and refill the drive axle according to the Pro-Mec Service Manual in Chapter 5. Drain, flush, and refill the hydraulic brake system; bleed the brake system.
Page 72: Lubrication Chart
Chapter 2 Section 1 MZ Tow Tractor LUBRICATION CHART Find No. Component Tie Rod Ends King Pins Wheel Bearings Transaxle Master Cylinder Power Steering Fluid Reservoir Motor Pivot Pins Figure 1-1. Lubrication Points CD373 2-1-6 Orig...
Page 73: Lubricants
Chapter 2 MZ Tow Tractor Section 1 LUBRICANTS Component/System Lubricant Type or Specification Adjusting Slides, Operator's Seat Multipurpose Lithium-based Grease Axle Hubs, Front Multipurpose Lithium-based Grease Axle, Rear (gears, differential, 80W90 Limited Slip Gear Oil and wet-disc brakes) Cab Door Handles...
Page 74: Adjustments
BEFORE PUTTING VEHICLE INTO SERVICE. Park Brake Adjustment When properly adjusted, the parking brake will prevent the MZ Tow Tractor from rolling when parked on a 10% grade. Engaging a properly adjusted parking brake should not require an excessive amount of force, however some slight resistance will be present when engaging.
Page 75: Instructions For Jacking And Positioning Vehicle
Chapter 2 MZ Tow Tractor Section 1 INSTRUCTIONS FOR JACKING AND POSITIONING VEHICLE Safety prerequisites Use only duty-rated jacks and jack stands. Floor jacks should be rated for a minimum of two tons. Jack stands should be rated for at least one ton each.
Page 76 Chapter 2 Section 1 MZ Tow Tractor (This page intentionally left blank.) CD373 2-1-10 Orig...
Page 77: Section 2: Troubleshooting
Chapter 2 MZ Tow Tractor Section 2 SECTION 2: TROUBLESHOOTING DRIVE AXLE Troubleshooting information for the drive axle can be found in the Pro-Mec Manual in Chapter 5 of this manual. HORN PROBLEM CAUSE CORRECTION 1. Horn works intermittently or (a) Blown fuse.
Page 78: Lights
Chapter 2 Section 2 MZ Tow Tractor LIGHTS PROBLEM CAUSE CORRECTION 1. Headlights working poorly, (a) Blown/damaged fuse or (a) Replace. intermittently, or not at all. circuit breaker. (b) Headlight bulb (sealed beam) (b) Replace. is blown. (c) Faulty headlight switch.
Page 79: Steering
Chapter 2 MZ Tow Tractor Section 2 STEERING PROBLEM CAUSE CORRECTION 1. Steering is difficult. (a) Lack of lubrication on axle. (a) Lubricate. (b) Low fluid in power steering (b) Check for leaks. Replace any fluid reservoir. damaged parts. Add fluid as needed.
Page 80: Wiring Diagrams
Section 2 MZ Tow Tractor WIRING DIAGRAMS The following pages contain wiring diagrams of the MZ Tow Tractor to assist maintenance personnel in troubleshooting the vehicle. Figure 2-1. Electrical Schematic (Sheet 1 of 6) ..............2-2-5 Figure 2-1. Electrical Schematic (Sheet 2 of 6) ..............2-2-6 Figure 2-1.
Page 81 Chapter 2 MZ Tow Tractor Section 2 Figure 2-1. Electrical Schematic (Sheet 1 of 6) CD373 2-1-5 Rev 3...
Page 82 Chapter 2 Section 2 MZ Tow Tractor Figure 2-1. Electrical Schematic (Sheet 2 of 6) 2-2-6 CD373 Rev 3...
Page 83 Chapter 2 MZ Tow Tractor Section 2 Figure 2-1. Electrical Schematic (Sheet 3 of 6) CD373 2-1-7 Rev 3...
Page 84 Chapter 2 Section 2 MZ Tow Tractor Figure 2-1. Electrical Schematic (Sheet 4 of 6) 2-2-8 CD373 Rev 3...
Page 85 Chapter 2 MZ Tow Tractor Section 2 Figure 2-1. Electrical Schematic (Sheet 5 of 6) CD373 2-1-9 Rev 3...
Page 86 Chapter 2 Section 2 MZ Tow Tractor Figure 2-1. Electrical Schematic (Sheet 6 of 6) 2-2-10 CD373 Rev 3...
Page 87 Chapter 2 MZ Tow Tractor Section 2 Figure 2-2. MZ Quick Charge Option (Sheet 1 of 3) CD373 2-1-11 Orig...
Page 88 Chapter 2 Section 2 MZ Tow Tractor Figure 2-2. MZ Quick Charge Option (Sheet 2 of 3) 2-2-12 CD373 Orig...
Page 89 Chapter 2 MZ Tow Tractor Section 2 Figure 2-2. MZ Quick Charge Option (Sheet 3 of 3) CD373 2-1-13 Orig...
Page 90 Chapter 2 Section 2 MZ Tow Tractor Figure 2-3. MZ Main Wiring Harness Diagram 2-2-14 CD373 Rev 3...
Page 91 Chapter 2 MZ Tow Tractor Section 2 Figure 2-4. MZ Body Wiring Harness Diagram CD373 2-1-15 Rev 3...
Page 92 Chapter 2 Section 2 MZ Tow Tractor (This page intentionally left blank.) 2-2-16 CD373 Orig...
Page 93: Section 3: Removal / Installation
Chapter 2 MZ Tow Tractor Section 3 SECTION 3: REMOVAL / INSTALLATION INTRODUCTION The following procedures for removal and installation of vehicle components outline the steps and precautions to take when removing items for replacement or repair of powertrain components including: (1) motor/transaxle assembly, (2) display gauge, (3) hydraulic brake pressure transducer, (4) electronic accelerator pedal assembly, (5) DC/DC converter, and (6) control panel assembly.
Page 94: Removal / Installation
Chapter 2 Section 3 MZ Tow Tractor REMOVAL / INSTALLATION ALWAYS REVIEW SAFETY PRECAUTIONS PRIOR TO PERFORMING WORK ON THIS EQUIPMENT. Operator/Passenger Seat Removal: Locate mounting nuts four (4) on underside of seat deck. Remove front two (2) mounting nuts from captive studs pressed into seat slider assembly.
Page 95: Main Power ("Ignition") Switch
Chapter 2 MZ Tow Tractor Section 3 Hold shifter assembly without knob UNDER mounting hole in approximate mounted position. Rotate shaft toward front of vehicle to reveal wiring attachment points. Attach wiring according to diagram. Rotate shifter to upright position. Slide shifter up through mounting hole.
Page 96: Steering Wheel
Chapter 2 Section 3 MZ Tow Tractor Plug brake line ports or drain brake fluid into appropriate container. Remove two (2) mounting bolts and nuts. Slide master cylinder off of push rod. Installation: Open console door. Slide master cylinder onto push rod.
Page 97: Tires And Wheels
Chapter 2 MZ Tow Tractor Section 3 Remove (4) mounting bolts. Slide steer valve assembly down through hole. Remove hydraulic lines. Installation: Attach hydraulic lines to steer valve (see Steering Column Assembly in Chapter 4, Section 2). Align steer valve with column so that line ports face toward front of vehicle.
Page 98: Hydraulic Steering Pump
Chapter 2 Section 3 MZ Tow Tractor Front Tire and Wheel Removal: Jack the front wheels off the ground using normal jacking procedures found in Chapter 2, Section 1, paragraph G. WARNING: IN SOME CASES, WHEEL IS EQUIPPED WITH RETAINING RING, AND IN OTHERS, WHEEL IS A TWO-PIECE, BOLT- TOGETHER DESIGN.
Page 99: Battery Removal/Replacement
Chapter 2 MZ Tow Tractor Section 3 Remove four (4) mounting bolts. Use long extension ratchet and matching wrenches below tractor. CAUTION: WIPE ALL CONNECTIONS CLEAN PRIOR TO OPENING SYSTEM. CAUTION: CAP OR PLUG ALL OPEN PORTS AND LINES. Note NOTE: Use back-up wrenches on all mating fittings.
Page 100: Service Brakes Removal/Installation
Chapter 2 Section 3 MZ Tow Tractor Hoist new battery above tractor, carefully lower into place. Connect battery. Service Brakes Removal/Installation Refer to Chapter 3, Section 5 for brake service instructions. 2-3-8 CD373 Orig...
Page 101 Chapter 3 MZ Tow Tractor Contents CHAPTER 3: OVERHAUL TABLE OF CONTENTS SECTION 1: OVERHAUL SCHEDULES................... 3-1-1 Recommended Overhaul Periods ................ 3-1-1 General ..................... 3-1-1 Steer Axle ......................3-1-1 Hydraulic Pump ....................3-1-1 Master Cylinder ..................... 3-1-1 Disc Brake Calipers ....................3-1-2 Powertrain ......................
Page 102 Chapter 3 Contents MZ Tow Tractor SECTION 5: DISC BRAKES ..................... 3-5-1 Introduction ......................3-5-1 Brake Pad Replacement ..................3-5-1 Unit Preparation ..................3-5-1 Front Caliper Removal ................3-5-1 Brake Pad Removal .................. 3-5-2 Cleaning and Inspection ................3-5-2 Brake Pad Installation ................3-5-3 Caliper Installation ..................
Page 103: Section 1: Overhaul Schedules
Chapter 3 MZ Tow Tractor Section 1 SECTION 1: OVERHAUL SCHEDULES RECOMMENDED OVERHAUL PERIODS General The following overhaul periods are approximate and can vary greatly due to different operating conditions. Units operating in extreme conditions such as high or low temperatures, long periods of sustained operation, continued operation in sand or dust or continued exposure to sea air or moisture require careful, regular inspections.
Page 104: Disc Brake Calipers
Chapter 3 Section 1 MZ Tow Tractor DISC BRAKE CALIPERS Calipers should be overhauled if piston seizure is evident, if leakage occurs around piston boot or if uneven braking persists after troubleshooting brake lines. POWERTRAIN Refer to Pro-Mec Manual in Chapter 5 for components of the powertrain.
Page 105: Section 2: Steer Axle Overhaul
Chapter 3 MZ Tow Tractor Section 2 SECTION 2: STEER AXLE OVERHAUL GENERAL If tractor has been properly lubricated and maintained and has not experienced damage to the steering system, the steering components will provide many hours of service without an overhaul. Should...
Page 106: Front Axle Spring Bushings Removal/Replacement
Chapter 3 Section 2 MZ Tow Tractor Replace caliper using procedure given in Chapter 3, Section 5, paragraph B.6. Install the wheel. FRONT AXLE SPRING BUSHINGS REMOVAL/REPLACEMENT This procedure is written with the assumption that both sets of bushings are to be changed. Brake caliper assemblies do not have to be removed for this procedure, however care must be observed not to drop the front axle further than is allowed by the flexible front brake hoses.
Page 107 Chapter 3 MZ Tow Tractor Section 2 Install the connecting rod to the spindle arms, securing the connecting rod ends to the spindle arms with the two (2) retainer nuts and cotter pins. With the wheels pointing straight forward, adjust the “toe-in” by turning the connecting rod until the centerline-to-centerline distance across the back of the tires is 0 to 1/16 inch longer than the centerline-to-centerline distance across the front of the tires.
Page 108 Chapter 3 Section 2 MZ Tow Tractor (This page intentionally left blank.) 3-2-4 CD373 Orig...
Page 109: Section 3: Hydraulic Pump Overhaul
Chapter 3 MZ Tow Tractor Section 3 SECTION 3: HYDRAULIC PUMP OVERHAUL GENERAL Hydraulic pump should be overhauled after 2500 hours or when internal or external leakage is evident. The hydraulic pump assembly can be divided into three main components: reservoir, pump section, and motor (refer to Figure 3.1).
Page 110 Chapter 3 Section 3 MZ Tow Tractor Tug Part Number: Manufacturer: Monarch Hydraulic M3-1-8026 Part Number: M-304-0260 OUTLET PORT 3/8 NPTF 1/ 4 NPTF BRACKET MOUNT Figure 3-1. Hydraulic Pump Assembly (P/N M3-1-8026) 3-3-2 CD373 Rev 3...
Page 111 Chapter 3 MZ Tow Tractor Section 3 Table 3-1. Hydraulic Pump Assembly (P/N M3-1-8026) Ref. Part Description Req'd 03142 PUMP ASSEMBLY, Gear Code 62 02625 PUMP ASSEMBLY, Gear Code 51 02650 PUMP ASSEMBlY, Gear Code 43 02624 PUMP ASSEMBlY, Gear Code 42...
Page 112 Chapter 3 Section 3 MZ Tow Tractor (This page intentionally left blank.) 3-3-4 CD373 Rev 2...
Page 115: Pump Installation
Chapter 3 MZ Tow Tractor Section 3 PUMP INSTALLATION Place pump and reservoir assembly into floor of right side service bin, reservoir end toward rear of vehicle. Attach hydraulic lines at elbows as labeled from removal. Attach assembly to floor using four (4) mounting bolts. Use long extension rachet and matching wrenches below tractor.
Page 116 Chapter 3 Section 3 MZ Tow Tractor (This page intentionally left blank.) 3-3-8 CD373 Orig...
Page 117: Section 4: Master Cylinder Disassembly And Assembly
Chapter 3 MZ Tow Tractor Section 4 SECTION 4: MASTER CYLINDER DISASSEMBLY AND ASSEMBLY MASTER CYLINDER REMOVAL Remove master cylinder as outlined below. (When it is necessary to repair the master cylinder during the warranty period, replace the cylinder as a unit instead of overhauling the cylinder with a service repair kit.)
Page 118: Master Cylinder Re-Assembly
Chapter 3 Section 4 MZ Tow Tractor Check all recesses, openings and internal passages to be sure they are open and free of foreign matter. Inspect the hydraulic master cylinder bore for etching, pitting or rust. Replace the master cylinder if any of these conditions exist.
Page 119: Master Cylinder Installation
Chapter 3 MZ Tow Tractor Section 4 Repeat steps (3) and (4) for the front brake outlet port with the rear brake outlet plugged. Tighten the plugs and attempt to depress the piston. The piston will resist depression after all air is expelled.
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Page 121: Section 5: Disc Brakes
SECTION 5: DISC BRAKES INTRODUCTION The following illustrations and procedures apply specifically to the MZ front disc brakes. The rear brake is a wet brake, integral to the drive axle. For rear brake information refer to Pro-Mec manual in Chapter 5.
Page 122: Brake Pad Removal
Chapter 3 Section 5 MZ Tow Tractor MOUNTING BOLTS Figure 5-1. Caliper Mounting Bolts Figure 5-2. Brake Line Connection Note NOTE: If only brake pads and linings are being replaced, omit step (e). Disconnect brake line from caliper and plug openings in caliper and line to prevent fluid loss and contamination (Figure 5-2).
Page 123: Brake Pad Installation
Chapter 3 MZ Tow Tractor Section 5 BRAKE HOSE BRAKE HOSE BOLT BLEED VALVE CALIPER HOUSING PAD RETAINER HOUSING RETAINER BOLT SLEEVE O-RING WASHER BRAKE HOSE OUTBOARD PAD AND LINING INBOARD PAD AND LINING Figure 5-3. Caliper Mounting If no defects are found, wipe clean the inside of the caliper including the four ears where bushings are to be installed.
Page 124: Caliper Installation
Chapter 3 Section 5 MZ Tow Tractor Install inboard pad and lining as shown (Figure 5-4). Position outer arc of pad against inner arc of caliper. Depress spring vee to collapse it and enable it to slip inside of piston cup. Snap pad into place.
Page 125: Check-Out
Chapter 3 MZ Tow Tractor Section 5 MOUNTING BOLTS ROTOR Figure 5-5. Caliper Mounting Bolts Check-Out Check brake pedal for sponginess or hard pedal. Drive vehicle slowly and make several slow speed stops. Check all brake fluid line fittings and caliper areas for fluid leakage.
Page 126 Chapter 3 Section 5 MZ Tow Tractor BRAKE HOSE BRAKE HOSE BOLT BLEED VALVE CALIPER HOUSING HOUSING PISTON RETAINER BOLT SLEEVE PAD RETAINER O-RING PISTON SEAL WASHER BRAKE HOSE CALIPER BOOT OUTBOARD PAD AND LINING INBOARD PAD AND LINING Figure 5-6. Front-Wheel Disc Brake Caliper...
Page 127 Chapter 3 MZ Tow Tractor Section 5 COMPRESSED Figure 5-7. Piston Removal Use just enough compressed air in caliper brake line port to force piston out. Excessive air may cause piston to be blown out of bore and become damaged.
Page 128: Cleaning And Inspection
Chapter 3 Section 5 MZ Tow Tractor Cleaning and Inspection Thoroughly clean all parts not in repair kit with denatured alcohol. Inspect caliper bore for scoring, nicks, corrosion or wear. Use crocus cloth to polish out any light corrosion. Replace caliper housing if bore will not clean up using crocus cloth.
Page 129: Installation
Chapter 3 MZ Tow Tractor Section 5 Installation Install caliper assembly, fill master cylinder, and bleed brake system as described in paragraph E of this section. Check-Out Check brake pedal for sponginess or hard pedal. Drive vehicle slowly and make several slow speed stops.
Page 130: Inspection
Chapter 3 Section 5 MZ Tow Tractor Inspection Inspect braking surfaces for evidence of corrosion, pitting, or scratches. Replace if scratched, corroded or pitted. Check the thickness and out of plane limits of the rotor. The minimum thickness should be 0.885" (front).
Page 131: Bleeding The Disc Brake System
Chapter 3 MZ Tow Tractor Section 5 BLEEDING THE DISC BRAKE SYSTEM General If the caliper was removed for overhaul, or if the brake hose or steel line was disconnected for any other reason, it will be necessary to bleed all air from the calipers and connecting lines.
Page 132: Pressure Bleeding
Chapter 3 Section 5 MZ Tow Tractor Pressure Bleeding If the equipment is available, pressure bleeding is faster, since the master cylinder does not have to be refilled several times. Pressure bleeding equipment must be of the diaphragm type. That is, it must have a rubber diaphragm between the air supply and the brake fluid to prevent air, moisture, oil and other contaminants from entering the hydraulic system.
Page 133 Chapter 4 MZ Tow Tractor Contents CHAPTER 4: ILLUSTRATED PARTS LIST TABLE OF CONTENTS SECTION 1: DESCRIPTION ..................... 4-1-1 Introduction ......................4-1-1 Using the Illustrated Parts List ................4-1-2 Figure and Index Number ................4-1-2 Part Number ..................... 4-1-3 Description and Quantity ................4-1-3 Effectivity....................
Page 134 Chapter 4 Contents MZ Tow Tractor Figure 2-23. Front Axle Assembly ............... 4-2-50 Figure 2-24. Front Axle Components ..............4-2-52 Figure 2-25. Rear Suspension ................4-2-54 Figure 2-26. Wheels and Tires ................4-2-56 Figure 2-27. Park Brake Assembly ..............4-2-58 Figure 2-28.
Page 135 INTRODUCTION The Illustrated Parts List (IPL) contained in this manual furnishes spare parts and replacement parts information as well as general part and assembly information necessary for maintenance of the TUG Model MZ Tow Tractor. CAUTION: FOR YOUR OWN PROTECTION, DO NOT USE SUBSTITUTE PARTS WITHOUT THE APPROVAL OF TUG.
Page 136 The Illustrated Parts List (IPL) provides an illustrated breakdown of components and systems which comprise the MZ Tow Tractor. Each IPL consists of a figure illustrating a group of related parts and a corresponding list identifying the parts by part number(s) and description. The quantity given in the list is for the particular assembly shown in the illustration and is not necessarily the quantity for the entire unit.
Page 137 Section 1 Part Number Parts are identified by part numbers assigned by TUG or, in the case of fasteners and related materials, by industry standard specification. In a few instances, TUG part numbers are not available. See the following illustration for further explanation of Part Numbers.
Page 138 To ensure that proper spares and replacement parts are obtained, it is recommended that all major components be procured directly from TUG. Use of parts not manufactured or supplied by TUG may void the warranty on the vehicle. When replacing structural fasteners, use Grade 8 or higher material.
Page 139 SECTION 2: ILLUSTRATED PARTS LIST INTRODUCTION The following illustrations and corresponding tables comprise the Illustrated Parts List (IPL) for the MZ Electric Tow Tractor. Refer to Section 1 of this Chapter for instructions on using the IPL to identify spare parts and replacement parts information.
Page 140 Chapter 4 Section 2 MZ Tow Tractor 25 26 28 29 21 22 Figure 2-1. Body Components 4-2-2 CD373 Rev 3...
Page 141 Chapter 4 MZ Tow Tractor Section 2 Table 2-1. Body Components Fig & Tug Part Description Effective Number MZ-10001K Frame Weldment Kit 1 & Up ¼-20 x ¾ Bolt, Hex Head Ø ¼-20 x ¾" Long " ¼ Washer, Lock ¼" ID "...
Page 142 Chapter 4 Section 2 MZ Tow Tractor 25 26 28 29 21 22 Figure 2-1. Body Components (Cont'd) 4-2-4 CD373 Rev 3...
Page 143 Chapter 4 MZ Tow Tractor Section 2 Table 2-1. Body Components (Cont'd) Fig & Tug Part Description Effective Number 1-26 Washer, Flat 3/8" ID 1 & Up 1-27 ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1¼" Long "...
Page 144 Chapter 4 Section 2 MZ Tow Tractor Figure 2-2. Body Components - Rear 4-2-6 CD373 Rev 3...
Page 145 MZ-10001K Frame Weldment Kit " 2-18 T6-200-105 Safety-Walk 12" x 60' (Price/Ft) " 2-19 MZ-10041 Stiffener, MZ Frame - Opt. As Req'd 2-20 MZ-10113 Strip, Rub, Mid Section - Opt. " 2-21 MZ-10114 Rail, Rub, Left Rear - Opt. "...
Page 146 Chapter 4 Section 2 MZ Tow Tractor Figure 2-2a. Body Components - Bottom View 4-2-8 CD373 Rev 3...
Page 147 Chapter 4 MZ Tow Tractor Section 2 Table 2-2a. Body Components - Bottom View Fig & Tug Part Description Effective Number 2a-1 MZ-10001K Frame Weldment Kit 1 & Up 2a-2 MZ-10116 Guard, Motor Cables - Opt. As Req'd 2a-3 MZ-10120 Guard, Steer Cylinder - Opt.
Page 148 Chapter 4 Section 2 MZ Tow Tractor Figure 2-3. Cab Assembly (Optional) 4-2-10 CD373 Rev 3...
Page 149 MZ Tow Tractor Section 2 Table 2-3. Cab Assembly (Optional) Fig & Tug Part Description Effective Number MZ-10057 Cab Assembly, Weldment - MZ As Req'd MZ-10050 Door, White Steel - L/H " MZ-10036 Door, Beige Vinyl - L/H " MZ-10034 Door, White Vinyl - L/H "...
Page 150 Chapter 4 Section 2 MZ Tow Tractor Figure 2-4. Cab Assembly Components (Optional) 4-2-12 CD373 Rev 3...
Page 151 Chapter 4 MZ Tow Tractor Section 2 Table 2-4. Cab Assembly Components (Optional) Fig & Tug Part Description Effective Number MZ-10057 Cab Assembly, Weldment As Req'd 5/16-18 x 1¼ Bolt, Hex Head Ø 5/16-18 x 1¼" Long " 5/16 Washer, Flat 5/16" ID "...
Page 152 Chapter 4 Section 2 MZ Tow Tractor Figure 2-5. Door Assembly - Left Side (Optional) 4-2-14 CD373 Rev 3...
Page 153 Chapter 4 MZ Tow Tractor Section 2 Table 2-5. Door Assembly - Left Side (Optional) Fig & Tug Part Description Effective Number MZ-10063 Insulation, L/H Door As Req'd CMA-504 Strip, Seal - Door, 16.5' Long " MZ-10050 Door, White Steel - L/H "...
Page 154 Chapter 4 Section 2 MZ Tow Tractor Figure 2-6. Door Assembly - Right Side (Optional) 4-2-16 CD373 Rev 3...
Page 155 Chapter 4 MZ Tow Tractor Section 2 Table 2-6. Door Assembly - Right Side (Optional) Fig & Tug Part Description Effective Number MZ-10064 Insulation, R/H Door As Req'd CMA-504 Strip, Seal - Door, 16.5' Long " MZ-10049 Door, White Steel - R/H "...
Page 156 Chapter 4 Section 2 MZ Tow Tractor Figure 2-7. Instrument Panel Assembly 4-2-18 CD373 Rev 3...
Page 157 Chapter 4 MZ Tow Tractor Section 2 Table 2-7. Instrument Panel Assembly Fig & Tug Part Description Effective Number T6-1010-159 Decal, "Made in USA" 1 & Up ML-26 Decal, "Caution" " TM1-1-6535 Switch, Dual Wiper - Opt. As Req'd M3-1-8108-1 Control, Directional with Sealed Switches 1 &...
Page 158 Chapter 4 Section 2 MZ Tow Tractor Figure 2-8. Seat Assembly 4-2-20 CD373 Rev 3...
Page 159 Chapter 4 MZ Tow Tractor Section 2 Table 2-8. Seat Assembly Fig & Tug Part Description Effective Number Washer, Flat 3/8" ID 1 & Up 3/8-16 x 1¼ Bolt, Hex Head Ø 3/8-16 x 1¼" Long " 3/8-16 Nut, Top Lock Hex 3/8-16 "...
Page 160 Chapter 4 Section 2 MZ Tow Tractor Figure 2-9. Accelerator Pedal Assembly 4-2-22 CD373 Rev 3...
Page 161 5/16-24 x 1 Bolt, Hex Head Ø 5/16-24 x 1" Long " 5/16 Washer, Flat 5/16" ID " 5/16-24 Nut, Flange Lock Hex 5/16-24 " MZ-10046 Grommet, 11/16 Rubber " HRN-MZ-80V-111 Harness, Main, MZ 80V " 4-2-23 CD373 Rev 3...
Page 162 Chapter 4 Section 2 MZ Tow Tractor Figure 2-10. Hydraulic System 4-2-24 CD373 Rev 3...
Page 163 Chapter 4 MZ Tow Tractor Section 2 Table 2-10. Hydraulic System Fig & Tug Part Description Effective Number 10-1 MZ-10003 Axle, Front 1 & Up 10-2 MT-1-1235 End, Tie Rod " 10-3 ------ Fitting, Grease " 10-4 5/16-18 Nut, Castellated with Pin 5/16-18 "...
Page 164 Chapter 4 Section 2 MZ Tow Tractor Figure 2-11. Hydraulic Pump Installation 4-2-26 CD373 Rev 3...
Page 165 Chapter 4 MZ Tow Tractor Section 2 Table 2-11. Hydraulic Pump Installation Fig & Tug Part Description Effective Number 11-1 M3-1-8026 Pump Assembly, Power Steer, 72V OHIO 1 & Up 11-2 5/16-18 Nut, Flange 5/16-18 " 11-3 MX4-10231 Mount, Isolator, Rubber "...
Page 166 Chapter 4 Section 2 MZ Tow Tractor Figure 2-12. Steering Column Assembly 4-2-28 CD373 Rev 3...
Page 167 Chapter 4 MZ Tow Tractor Section 2 Table 2-12. Steering Column Assembly Fig & Tug Part Description Effective Number 12-1 660-1-3028 Valve, Steer 1 & Up 12-2 TM1-ND-5266 Fitting, Male Boss 45° - 6JIC Male " 12-3 Washer, Flat 3/8" ID "...
Page 168 Chapter 4 Section 2 MZ Tow Tractor Figure 2-13. Controller Assembly 4-2-30 CD373 Rev 3...
Page 169 Chapter 4 MZ Tow Tractor Section 2 Table 2-13. Controller Assembly Fig & Tug Part Description Effective Number MZ-10008 Controller Component Kit 1 & Up 13-1 10-32 x 1 Bolt, Countersunk Ø 10-32 x 1" Long " 13-2 ¼-28 x ¾...
Page 170 Chapter 4 Section 2 MZ Tow Tractor Figure 2-14. Circuit Breaker Panel Components 4-2-32 CD373 Rev 3...
Page 171 14-14 660-4-0741-5 Circuit Breaker #1, 20 Amp (Flash PWR) " 14-15 660-4-0741-5 Circuit Breaker #2, 20 Amp " (Head, Rev. & Work Light Switches) 14-16 T6-7013-209 Relay, Horn " " 14-17 HRN-MZ-80V-112 Harness, Body, 12V, MZ 4-2-33 CD373 Rev 3...
Page 172 Chapter 4 Section 2 MZ Tow Tractor Figure 2-15. Battery Installation 4-2-34 CD373 Rev 3...
Page 173 Chapter 4 MZ Tow Tractor Section 2 Table 2.-15. Battery Installation Fig & Tug Part Description Effective Number 15-1 M3-1-1210-1 Battery, Deka 80V 500 Amp Hours - Opt. As Req'd M3-1-1210-2 Battery, Exide 80V 500 Amp Hours - Opt. "...
Page 174 Chapter 4 Section 2 MZ Tow Tractor Figure 2-16. Battery Connectors 4-2-36 CD373 Rev 3...
Page 175 Chapter 4 MZ Tow Tractor Section 2 Table 2-16. Battery Connectors Fig & Tug Part Description Effective Number 16-1 42-100-700 Connector, Green SB350 1 & Up 42-100-700 Connector, Green SB350 - Opt. As Req'd MX4-10250 Connector, Grey SB350, 4/0 with Terminals - Opt.
Page 176 Chapter 4 Section 2 MZ Tow Tractor Figure 2-17. Rapid Charge Assembly (Optional) 4-2-38 CD373 Rev 3...
Page 177 Chapter 4 MZ Tow Tractor Section 2 Table 2-17. Rapid Charge Assembly (Optional) Fig & Tug Part Description Effective Number 17-1 440E-99017 Box, Rapid Charge Connector - Weldment As Req'd 17-2 BLE-0002-4 Hinge, Enclosure - Weldment " 17-3 BLE-0002-3 Lid, Enclosure - Weldment "...
Page 178 Chapter 4 Section 2 MZ Tow Tractor Figure 2-18. Front and Rear Lights 4-2-40 CD373 Rev 3...
Page 179 Chapter 4 MZ Tow Tractor Section 2 Table 2-18. Front and Rear Lights Fig & Tug Part Description Effective Number 18-1 MZ-10017 Tail Light, Low Profile 1 & Up 18-2 Washer, Lock M6 " 18-3 Washer, Flat M6 " 18-4...
Page 180 Chapter 4 Section 2 MZ Tow Tractor Figure 2-19. Inching Control Assembly (Optional) 4-2-42 CD373 Rev 3...
Page 181 Chapter 4 MZ Tow Tractor Section 2 Table 2-19. Inching Control Assembly (Optional) Fig & Tug Part Description Effective Number 19-1 MX4-10076 Mount, Inching Control 1 & Up 19-2 660-ND-1920 Relief, Strain, ¾" As Req'd 19-3 660-1-3438 Block, Contact - N.O. (Forward & Reverse) "...
Page 182 Chapter 4 Section 2 MZ Tow Tractor Figure 2-20. Dual Wipers Assembly (Optional) 4-2-44 CD373 Rev 3...
Page 183 Chapter 4 MZ Tow Tractor Section 2 Table 2-20. Dual Wipers Assembly (Optional) Fig & Tug Part Description Effective Number 20-1 MX4-10089 Closeout, Wiper Linkage As Req'd 20-2 TM1-1-6535 Switch, Dual Wiper " 20-3 TM1-1-6536 Washer, Spacing - Dual Wipers "...
Page 184 Chapter 4 Section 2 MZ Tow Tractor Figure 2-21. Horn Assembly 4-2-46 CD373 Rev 3...
Page 185 Chapter 4 MZ Tow Tractor Section 2 Table 2-21. Horn Assembly Fig & Tug Part Description Effective Number 21-1 T6-7013-207 Horn Assembly 1 & Up 21-1a ------ Horn, with Terminal Applications " 21-1b Bolt, Hex Head Ø 8mm " 21-1c...
Page 186 Chapter 4 Section 2 MZ Tow Tractor Figure 2-22. Front Suspension 4-2-48 CD373 Rev 3...
Page 187 Chapter 4 MZ Tow Tractor Section 2 Table 2-22. Front Suspension Fig & Tug Part Description Effective Number 22-1 5/8-11 x 4½ Bolt, Hex Head Ø 5/8-11 x 4½" Long 1 & Up 22-2 MZ-10001-19 Hanger, Leaf Spring - Front (Part of Frame Wldmt) "...
Page 188 Chapter 4 Section 2 MZ Tow Tractor Figure 2-23. Front Axle Assembly 4-2-50 CD373 Rev 3...
Page 189 Chapter 4 MZ Tow Tractor Section 2 Table 2.-23. Front Axle Assembly Fig & Tug Part Description Effective Number 23-1 MX4-10067-3 Hub/Rotor Kit 1 & Up 23-2 ------ Knuckle, L/H - Weldment " 23-3 TM1-ND-8077-LH Caliper, Disk Brake - L/H "...
Page 190 Chapter 4 Section 2 MZ Tow Tractor Figure 2-24. Front Axle Components 4-2-52 CD373 Rev 3...
Page 191 Chapter 4 MZ Tow Tractor Section 2 Table 2-24. Front Axle Components Fig & Tug Part Description Effective Number 24-1 MT-1-1225 Nut, Slotted Hex 1¼-12 1 & Up 24-2 ------ Spacer, Top King Pin " 24-3 ------ Seal, Grease - Top "...
Page 192 Chapter 4 Section 2 MZ Tow Tractor Figure 2-25. Rear Suspension 4-2-54 CD373 Rev 3...
Page 193 Chapter 4 MZ Tow Tractor Section 2 Table 2-25. Rear Suspension Fig & Tug Part Description Effective Number 25-1 MZ-10002 Axle/Motor Assembly, Rear 1 & Up 25-2 MZ-10005 Pin, Motor/Axle Pivot " 25-3 ¼-20 x 3¼ Bolt, Hex Head Ø ¼-20 x 3¼" Long "...
Page 194 Chapter 4 Section 2 MZ Tow Tractor Figure 2-26. Wheels and Tires 4-2-56 CD373 Rev 3...
Page 195 As Req'd 26-2 T6-2400-164 Tire, Tug Tuff, 6.90 x 9.0, with Liner 1 & Up T6-2400-165 Tire, Tug Tuff, 6.50 x 10, with Liner - DAL Opt. As Req'd 26-3 T6-2400-168 Wheel, Tug Tuff, 4.0 x 9.0 1 & Up T6-1300-125 Wheel, 2-Pieces, 10 x 5.0 - DAL Opt.
Page 196 Chapter 4 Section 2 MZ Tow Tractor Figure 2-27. Park Brake Assembly 4-2-58 CD373 Rev 3...
Page 197 Chapter 4 MZ Tow Tractor Section 2 Table 2-27. Park Brake Assembly Fig & Tug Part Description Effective Number 27-1 MZ-10030 Mount, Park Brake Handle 1 & Up 27-2 T6-8005-103 Bushing, Hand Brake " 27-3 T6-8005-101 Lever, Hand Brake "...
Page 198 Chapter 4 Section 2 MZ Tow Tractor Figure 2-28. Park Brake Cable Assembly 4-2-60 CD373 Rev 3...
Page 199 Chapter 4 MZ Tow Tractor Section 2 Table 2-28. Park Brake Cable Assembly Fig & Tug Part Description Effective Number 28-1 MZ-10012 Cable, Park Brake Primary 1 & Up 28-2 MZ-10047 Anchor, Park Brake Cable " 28-3 MZ-10023 Arm, Park Brake "...
Page 200 Chapter 4 Section 2 MZ Tow Tractor Figure 2-29. Brake Pedal Assembly 4-2-62 CD373 Rev 3...
Page 201 Chapter 4 MZ Tow Tractor Section 2 Table 2-29. Brake Pedal Assembly Fig & Tug Part Description Effective Number 29-1 MX4-10056 Pedal Assembly, Brake 1 & Up 29-2 MZ-1001-29 Mount, Brake Pedal " 29-3 M3-1-8168 Pin, Brake Pedal Pivot "...
Page 202 Chapter 4 Section 2 MZ Tow Tractor Figure 2-30. Front Brake Lines 4-2-64 CD373 Rev 3...
Page 203 Chapter 4 MZ Tow Tractor Section 2 Table 2-30. Front Brake Lines Fig & Tug Part Description Effective Number 30-1 T6-9011-571 Master Cylinder - Aluminum 1 & Up 30-2 660-ND-1397 Adapter, Brake " 30-3 MH-ND-565 Line, Brake, 10" " 30-4 T6-6011-141 Line, Brake, 20"...
Page 204 Chapter 4 Section 2 MZ Tow Tractor Figure 2-31. Rear Brake Lines 4-2-66 CD373 Rev 3...
Page 205 Chapter 4 MZ Tow Tractor Section 2 Table 2-31. Rear Brake Lines Fig & Tug Part Description Effective Number 31-1 5-100-101 Line, Brake, 51" 1 & Up 31-2 T6-8011-121 Connector " 31-3 MX4-10314 Hose Assembly, Brake, 87", SS Teflon "...
Page 206 Chapter 4 Section 2 MZ Tow Tractor Figure 2-32. Front Brake Calipers 4-2-68 CD373 Rev 3...
Page 207 Chapter 4 MZ Tow Tractor Section 2 Table 2-32. Front Brake Calipers Fig & Tug Part Description Effective Number 32-1 TM1-ND-8077-LH Caliper, Steer Axle 1 & Up TM1-ND-8077-RH Caliper, Steer Axle " 32-2 TM1-ND-8076 Pad Set, Brake Caliper (Semi-Metallic) "...
Page 208 Chapter 4 Section 2 MZ Tow Tractor (This page intentionally left blank.) 4-2-70 CD373 Rev 3...
Page 209 Chapter 4 MZ Tow Tractor Section 3 SECTION 3: NUMERICAL INDEX Tug Part Number Description Fig & Ind# ——— Bracket 21-1c ——— Bracket, L 21-1d ——— Caliper, Single Piston, L/H (Note 1) 32-6 ——— Caliper, Single Piston, R/H (Note 1) 32-6 ———...
Page 210 Chapter 4 Section 3 MZ Tow Tractor Tug Part Number Description Fig & Ind# ¼ Washer, Flat ¼” ID ¼ Washer, Flat ¼” ID 19-8 ¼ Washer, Flat ¼” ID 20-10 ¼ Washer, Flat ¼” ID 21-2 ¼ Washer, Flat ¼” ID 29-13 ¼...
Page 211 Chapter 4 MZ Tow Tractor Section 3 Tug Part Number Description Fig & Ind# ¼-20 x ¾ Bolt, Socket Head Ø ¼-20 x ¾” Long ¼-20 x ¾ Bolt, Socket Head Ø ¼-20 x ¾” Long ¼-20 x 1 Bolt, Hex Head Ø ¼-20 x 1" Long 19-10 ¼-20 x 1...
Page 212 Chapter 4 Section 3 MZ Tow Tractor Tug Part Number Description Fig & Ind# 3/32 x 7/8 Pin, Cotter Ø 3/32 x 7/8" Long 28-6 3/32 x 7/8 Pin, Cotter Ø 3/32 x 7/8" Long 29-6 Washer, Flat 3/8" ID 12-3 Washer, Flat 3/8"...
Page 213 Chapter 4 MZ Tow Tractor Section 3 Tug Part Number Description Fig & Ind# 5/16 Washer, Flat 5/16" ID 5/16 Washer, Flat 5/16" ID 5/16 x ½ Screw Ø 5/16 x ½” Long 14-13 5/16-18 Nut, Castellated with Pin 5/16-18...
Page 214 CMA-451 Window, R/H Double Slide 6-14 CMA-504 Strip, Seal - Door, 16.5' Long CMA-504 Strip, Seal - Door, 16.5' Long HRN-MZ-80V-111 Harness, Main, MZ 80V HRN-MZ-80V-112 Harness, Body, 12V, MZ 14-17 HRN-MZ-80V-114 Harness, Rear Inching Control 19-11 M12-1.75 x 25 Bolt, Hex Head M12-1.75 x 25mm Long...
Page 215 Chapter 4 MZ Tow Tractor Section 3 Tug Part Number Description Fig & Ind# M3-1-1048 Decal, Electrical 2-14 M3-1-1050 Decal, “Caution: Max. Speed” 7-14 M3-1-1059 Button, Horn - Two-Wire Isolated Ground 12-9 M3-1-1210-1 Battery, Deka 80V 500 Amp Hours - Opt.
Page 216 Chapter 4 Section 3 MZ Tow Tractor Tug Part Number Description Fig & Ind# M8-1¼ Nut, Hex M8-1¼ 18-8 M8-1¼ x 16 Bolt, Hex Head Ø M8-1¼ x 16mm Long 13-4 MD-CB1-127 Bushing 1-36 MD-CB1-127 Bushing 29-4 MD-CB21-121 Clip 30-10 MG-1-320 Trim-Lock, 12.5' Long...
Page 217 Chapter 4 MZ Tow Tractor Section 3 Tug Part Number Description Fig & Ind# MX4-10084 Mount, Power Steer Pump, Modified 11-4 MX4-10089 Closeout, Wiper Linkage 20-1 MX4-10100 Glass, Rear Window - Raised Cab MX4-10102 Windshield, Front MX4-10109 Link, Wiper Blades...
Page 218 Chapter 4 Section 3 MZ Tow Tractor Tug Part Number Description Fig & Ind# MX4-10279 Battery Monitor ID Device (BMID), Exide 80V Batteries - Opt. 15-9 MX4-10280 Battery Monitor ID Device (BMID), Deka 80V Batteries - Opt. 15-9 MX4-10281 Hose, Brake...
Page 219 Chapter 4 MZ Tow Tractor Section 3 Tug Part Number Description Fig & Ind# MZ-10008-10 Panel, Controller Mount 14-1 MZ-10008-11 Bar, Buss, L/H 13-9 MZ-10008-12 Bar, Buss, R/H 13-10 MZ-10008-13 Bar, Buss, Small 13-11 MZ-10008-2 Converter, DC/DC 13-12 MZ-10008-3 Fuse, 50 Amp...
Page 220 4-11 MZ-10039 Battery, Deka, 80V, 420 AH, Gel - Opt. 15-1 MZ-10040 Clevis, Park Brake Arm 28-8 MZ-10041 Stiffener, MZ Frame - Opt. 2-19 MZ-10045 Charger, Ametek, 80V, 451-510 AH - Opt. MZ-10046 Grommet, 11/16 Rubber MZ-10046 Grommet, 11/16", Rubber...
Page 221 Safety-Walk 12" x 60' (Price/Ft) 2-18 T6-2400-164 Tire, Tug Tuff, 6.90 x 9.0, with Liner 26-2 T6-2400-165 Tire, Tug Tuff, 6.50 x 10, with Liner - DAL Opt. 26-2 T6-2400-166 Tire, Tug Tuff, 8.00 x 16.5 26-8 T6-2400-168 Wheel, Tug Tuff, 4.0 x 9.0...
Page 222 Chapter 4 Section 3 MZ Tow Tractor Tug Part Number Description Fig & Ind# T6-3001-60031 Cap, Grease 24-14 T6-3003-105 Nut, ½-20 UNF Tapered Wheel 24-15 T6-4014-103 Hitch Assembly, E-Standard T6-4014-122 Bracket, Hitch, Extension - DAL Opt. T6-4014-123 Bracket, Hitch Extension T6-4014-130 Bracket, Hitch Extension - Opt.
Page 223 Chapter 4 MZ Tow Tractor Section 3 Tug Part Number Description Fig & Ind# T6-8013-145 Bolt, Brake Hose 30-15 T6-8013-145 Bolt, Brake Hose 32-11 T6-8013-147 Washer, Brake Hose 30-14 T6-8013-147 Washer, Brake Hose 32-7 T6-8013-157 Piston 32-5 T6-8013-165 Screw, Bleeder, Delco...
Page 224 Chapter 4 Section 3 MZ Tow Tractor Tug Part Number Description Fig & Ind# TM1-ND-8075K Seal Kit, Front Calipers 32-4 TM1-ND-8076 Pad Set, Brake Caliper (Semi-Metallic) 32-2 TM1-ND-8077B Bolt, Caliper Mounting 32-10 TM1-ND-8077B Pin, Caliper Mounting 23-4 TM1-ND-8077-LH Caliper, Disk Brake - L/H...
Page 225 Chapter 4 MZ Tow Tractor Section 4 SECTION 4: ALPHABETICAL INDEX Tug Part Number Description Fig & Ind# M3-1-8140 Absorber, Shock 22-16 M3-1-8140 Absorber, Shock 25-10 MZ-10016 Accelerator Assembly T6-600-112 Adapter 30-5 660-ND-1397 Adapter, Brake 30-2 MZ-10100 Adapter, Door Linkage...
Page 226 Chapter 4 Section 4 MZ Tow Tractor Tug Part Number Description Fig & Ind# T6-8013-145 Bolt, Brake Hose 30-15 T6-8013-145 Bolt, Brake Hose 32-11 TM1-ND-8077B Bolt, Caliper Mounting 32-10 10-32 x 1 Bolt, Countersunk Ø 10-32 x 1" Long 13-1 M12-1.75 x 25...
Page 227 Chapter 4 MZ Tow Tractor Section 4 Tug Part Number Description Fig & Ind# 5/16-24 x 1 Bolt, Hex Head Ø 5/16-24 x 1" Long 5/8-11 x 4½ Bolt, Hex Head Ø 5/8-11 x 4½” Long 22-1 5/8-11 x 6 Bolt, Hex Head Ø...
Page 228 Button, Horn - Two-Wire Isolated Ground 12-9 660-1-3436 Button, Push - Green Head 19-5 MZ-10057 Cab Assembly, Weldment MZ-10057 Cab Assembly, Weldment - MZ MX4-10063 Cable, Battery (-) 15-4 MX4-10239 Cable, Battery (-) with 4/0 - Opt. 15-4 MX4-10062 Cable, Battery (+)
Page 229 Chapter 4 MZ Tow Tractor Section 4 Tug Part Number Description Fig & Ind# 660-4-0741-5 Circuit Breaker #3, 20 Amp (Horn, Cab, Beacon) 14-9 ——— Clamp, Hose IDEAL 5040 MZ-10040 Clevis, Park Brake Arm 28-8 MZ-10011 Clevis, with ¼ Throat for ¼-28...
Page 230 Chapter 4 Section 4 MZ Tow Tractor Tug Part Number Description Fig & Ind# ML-26 Decal, “Caution” T-430 Decal, “Caution” 7-10 M3-1-1050 Decal, “Caution: Max. Speed” 7-14 12960001 Decal, “Fasten Safety Belt” 7-15 T-A12 Decal, “Headlight” 7-21 T-A45 Decal, “Heater” - Opt.
Page 231 MZ-10001-19 Hanger, Leaf Spring - Front (Part of Frame Wldmt) 22-2 MZ-10001-20 Hanger, Leaf Spring - Rear (Part of Frame Wldmt) 22-9 HRN-MZ-80V-112 Harness, Body, 12V, MZ 14-17 HRN-MZ-80V-111 Harness, Main, MZ 80V HRN-MZ-80V-114 Harness, Rear Inching Control 19-11 CD373...
Page 232 Chapter 4 Section 4 MZ Tow Tractor Tug Part Number Description Fig & Ind# ——— Harness, Relay to Horn 21-5 MZ-10026 Headlight Assembly, LED 18-5 MX4-10154 Headliner, Foam 3-14 M3-1-8009 Heater M3-1-8013 Hinge, Console Door 1-13 MX4-10153 Hinge, Control Closeout...
Page 233 Chapter 4 MZ Tow Tractor Section 4 Tug Part Number Description Fig & Ind# ——— Knuckle, L/H - Weldment 24-8a ——— Knuckle, R/H - Weldment 23-6 ——— Knuckle, R/H - Weldment 24-8b MZ-10069 Latch, Two Rotor L/H MZ-10070 Latch, Two Rotor R/H BLE-1-2663 Lever Assembly, Manual Release - Opt.
Page 234 Chapter 4 Section 4 MZ Tow Tractor Tug Part Number Description Fig & Ind# MX4-10155 Mount, Heater MX4-10076 Mount, Inching Control 19-1 MX4-10231 Mount, Isolator, Rubber 11-3 MZ-10001-8 Mount, Motor Pivot, L/H - Wldmt (Part of Frame) 25-8 MZ-10001-7 Mount, Motor Pivot, R/H - Wldmt (Part of Frame)
Page 235 Chapter 4 MZ Tow Tractor Section 4 Tug Part Number Description Fig & Ind# T6-3001-60028 Nut, Spindle 24-12 ¼-20 Nut, Top Lock Hex ¼-20 25-4 ½-13 Nut, Top Lock Hex ½-13 25-13 ½-20 Nut, Top Lock Hex ½-20 22-13 ½-20 Nut, Top Lock Hex ½-20...
Page 236 Chapter 4 Section 4 MZ Tow Tractor Tug Part Number Description Fig & Ind# TM1-1-6534 Pin, Unitized Setup - Dual 20-12 MT-1-2061 Pin, Wiper Link 20-9 T6-8013-157 Piston 32-5 MX4-10215 Plate Weldment, Front Pintle - Opt. T6-9011-149 Plate, Data - Draw Bar...
Page 237 MZ-10096 Spring, Throttle 27-10 MZ-10096 Spring, Throttle 29-17 M3-2-1051 Stand, Flashing Light - Opt. 18-10 MZ-10041 Stiffener, MZ Frame - Opt. 2-19 MX4-10251 Strain Relief, 4/0 25-26 MX4-10251 Strain Relief, 4/0 - Opt. 25-26 T6-9003-153 Strip, Foam, Rear, 8 ft.
Page 238 T6-6011-111 31-4 T6-2400-171 Tire, Mud/Snow, 8.75 x 16.5 - Opt. 26-8 T6-2400-165 Tire, Tug Tuff, 6.50 x 10, with Liner - DAL Opt. 26-2 T6-2400-164 Tire, Tug Tuff, 6.90 x 9.0, with Liner 26-2 T6-2400-166 Tire, Tug Tuff, 8.00 x 16.5...
Page 239 Chapter 4 MZ Tow Tractor Section 4 Tug Part Number Description Fig & Ind# Washer, Flat 3/8" ID 12-3 Washer, Flat 3/8" ID 1-26 Washer, Flat 3/8" ID Washer, Flat 3/8" ID 3-11 Washer, Flat 3/8" ID Washer, Flat 3/8" ID 5/16 Washer, Flat 5/16"...
Page 240 MZ-10004-1 Wheel, 6.75 x 16.5 26-7 M3-1-8020 Wheel, Steer - 14" Diameter, with Boot 12-7 T6-2400-168 Wheel, Tug Tuff, 4.0 x 9.0 26-3 T6-2400-186 Wheel/Tire Assembly, Front 26-1 T6-2400-200 Wheel/Tire Assembly, Front, 6.5 x 10 TT - DAL Opt. 26-1 MZ-10004 Wheel/Tire Assembly, Rear, 8.00 x 16.5...
Page 241 Chapter 5 MZ Tow Tractor Contents CHAPTER 5: APPENDICES TABLE OF CONTENTS SECTION 1: PERIODIC MAINTENANCE CHECKLIST ............5-1-1 SECTION 2: ADDITIONAL INFORMATION & VENDOR PUBLICATIONS ......5-2-1 Description ......................5-2-1 5-TOC-i CD373 Orig...
Page 242 Chapter 5 Contents MZ Tow Tractor (This page intentionally left blank.) 5-TOC-ii CD373 Orig...
Page 243 Chapter 5 MZ Tow Tractor Section 1 SECTION 1: PERIODIC MAINTENANCE CHECKLIST TUG Model MZ Tow Tractor Serial Number: Date Manufactured: Date: ID Number: Service Requirement in Hours Daily 1000 2000 3000 Check for Working Controls Check Battery Charge Level...
Page 244 Chapter 5 Section 1 MZ Tow Tractor (This page intentionally left blank.) 5-1-1 CD373 Orig...
Page 245 Chapter 5 MZ Tow Tractor Section 2 SECTION 2: ADDITIONAL INFORMATION & VENDOR PUBLICATIONS DESCRIPTION The following pages/booklets contain additional information relevant to the operation and service of the MZ Tow Tractor. CD373 5-2-1 Orig...
Page 246 Chapter 5 Section 2 MZ Tow Tractor (This page intentionally left blank.) 5-2-2 CD373 Orig...
Page 247 Nome/Name Reparto/Departement Firma/Signature Redatto da / Prepared by: __________________ _____________________ ___________________ Verificato da / Checked by:_________________ _____________________ ___________________ Approvato da / Approved by________________ _____________________ ___________________ PMS701 HS-TR STD VERSION WHEEL DRIVE UNITS Pag. 1...
Page 248 Indice PMS701 HS-TR Index STD version Indice: Index: Caratteristiche fondamentali Main characteristics Dati tecnici Technical data Fissaggio del ponte Fixing details Manutenzione riduttore Gearbox maintenance Manutenzione differenziale Differential box maintenance Manutenzione freno Brake maintenance Lista ricambi Spare part list Disassemblaggio / assemblaggio Disassembly / assembly Descrizione revisioni Revisions account...
Page 249 Caratteristiche fondamentali PMS701 HS-TR Main characteristics STD version Il PMS 701 HS-TR è un ponte - non portante - PMS 701 HS-TR is a axle, that cannot sustain studiato per l’applicazione su trattori elettrici full load, designed for electrical traction, where dove è...
Page 250 Dati tecnici PMS701 HS-TR Technical data STD version PMS701– HS-TR -p PMS701– HS - TR - p Ponte con sistema di frenatura, in camera Axle with braking system in separate separata: freno di servizio (dinamico) ad chamber: hydraulic service brake azionamento idraulico freno...
Page 251 Dati tecnici PMS701 HS-TR Technical data STD version Pag. 5...
Page 252 Fissaggio del ponte PMS701 HS-TR Fixing details STD version L’assale è dotato di bracci (eventualmente The axle is provided with arms (eventually equipaggiati con boccole) per il fissaggio a equipped with ear-rings) of frame fixing and telaio e di bracci di posizionamento per il positioning arms for fixing damper system fissaggio del sistema di ammortizzazione as exemplified in the enclosed drawings...
Page 253 Manutenzione riduttore PMS701 HS-TR Gearbox maintenance STD version I riduttori vengono forniti senza olio. Per The reduction gearboxes are supplied il riempimento utilizzare i tappi di carico, without oil. For oil-filling operations, use livello, scarico olio riduttore come indicato the refill plug, the level plug and the drain in fig.3.
Page 254 Differenziale e sensore PMS701 HS-TR Differential gear and sensor STD version Il differenziale è posizionato a lato della The differential gear is installed inside the calotta motore (vedi fig.4) ed è lubrificato left side flange, looking from the tractor con lo stesso olio del riduttore adiacente. seat, of the electric motor and it’s lubri- cated with the same oil of the near gearbox Nella calotta motore dal lato opposto al...
Page 255 Manutenzione freno PMS701 HS– TR Brake maintenance STD version Il freno è fornito senza olio. Per il The brake cartridge is supplied without riempimento utilizzare i tappi di carico, oil. For oil-filling operations, use the refill livello, scarico olio freno come indicato in plug, the level plug and the drain plug as fig.6.
Page 256 Manutenzione freno PMS701 HS–TR Brake maintenance STD version Il manicotto M10x1(*) serve come attacco The M10x1(*) plug is used as connection del freno di servizio idraulico (vedi fig 7). to the hydraulic service brake circuit (see Lo spurgo posto a lato della leva freno fig 7).
Page 257 Manutenzione freno PMS701 HS-TR Brake maintenance STD version Smontaggio/Montaggio Unità Freni Brake disassembly/assembly procedure -descrizione generale -general description E’ necessario scaricare l’olio sia del You have to drain the oil both from the gruppo freno che del riduttore rimuovendo i brake disc chamber and from the reduction tappi (76 e 78 magnetico) posti in basso e i...
Page 258 Manutenzione freno PMS701 HS-TR Brake maintenance STD version Sostituzione dei Dischi Freno Replace of the Brake Discs Il pacco è composto da 6 controdischi (9) The brake discs unit is made of 6 steel e 5 dischi di attrito (53) tra loro alternati e discs (9) and 5 friction discs (53), ordered disposti in modo che il primo e l'ultimo in an alternate way (the first one and the...
Page 259 Manutenzione freno PMS701 HS-TR Brake maintenance STD version Cospargere il bordo della scatola con pasta Lay a coat of sealant on the cartridge sigillante reinserire riduttore contact surface. Insert the gearbox, centre centrandosi sulle 4 spine guida (74), quindi, on its 4 pins (74) and, using a rubber aiutandosi con un martello di gomma, hammer, fine-tune the cartridge position posizionare la scatola fino a chiusura.
Page 260 Manutenzione freno PMS701 HS-TR Brake maintenance STD version ATTENZIONE ! ATTENTION ! ciascun riduttore devono essere Every reduction gearbox need to be filled immesse le seguenti quantità di olio: with the following oil quantities: -lato sensore di velocità: 0.7 ÷ 0.8 litri -speed sensor side: 0.7 ÷...
Page 261 Lista ricambi PMS701 HS-TR Spare parts STD VERSION In caso di richiesta ricambi, identificare e It is necessary to identify the model and specificare il modello del prodotto ed il N° the serial number on the name-plate of the di serie rilevabili sulla targhetta del ridutto- gearbox (see fig 11) while asking for spare re (vedi fig 11).
Page 262 Lista ricambi PMS701 HS-TR Spare parts STD VERSION Lato destro (Sensore velocità) Right side (Speed sensor) Lato sinistro (Differenziale) Left side (Differential gear) Pag. 16...
Page 263 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: riduttore / unità freni Tab. A Spare parts list: gearbox / brake unit Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà KIT ricambi ►KIT.7004.0 010.0050...
Page 264 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: riduttore / unità freni Tab. A Spare parts list: gearbox / brake unit Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà KIT ricambi 381.0042 Left flange / flansch / Flangia intermedia SX...
Page 265 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: riduttore / unità freni Tab. A Spare parts list: gearbox / brake unit Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà KIT ricambi (prosegue da pag.1/continues from page 18) ►KIT.7020.0...
Page 266 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: riduttore / unità freni Tab. A Spare parts list: gearbox / brake unit Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà KIT ricambi (prosegue da pag.19/continues from page 19 ) ►KIT.7015.0...
Page 267 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: riduttore / unità freni Tab. A Spare parts list: gearbox / brake unit Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà KIT ricambi ►KIT.7004.0 CR1.0033...
Page 268 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: riduttore / unità freni Tab. A Spare parts list: gearbox / brake unit Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà KIT ricambi DM0.0011 Spherical head nut/ Wurfen zum...
Page 269 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: riduttore / unità freni Tab. A Spare parts list: gearbox / brake unit Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà KIT ricambi MOL.0019 Spring / Feder / Molla Distanziatore elastico...
Page 270 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: riduttore / unità freni Tab. A Spare parts list: gearbox / brake unit Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà KIT ricambi TAP.0025 Screw Plug / Verschraubung / Tappo cieco con rondella...
Page 271 Lista ricambi PMS701 HS-TR Spare parts STD version Pag. 25...
Page 272 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: differenziale / ruota fonica Tab. B Spare parts list: differential gear / tone wheel Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà...
Page 273 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: differenziale / ruota fonica Tab. B Spare parts list: differential gear / tone wheel Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà...
Page 274 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: differenziale / ruota fonica Tab. B Spare parts list: differential gear / tone wheel Part N° Ref. N° Designation Q.ty Spare part KIT Teil-Nr Bestell-Nr Bezeichnung M.ge Posiz. Codice Descrizione Q.tà...
Page 275 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà PAC.0001.0 Brake disc unit MOL.0021 Pacco freni...
Page 276 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà KIT.7008.4 First reduction set R.17.5 AE0.0009 Prima trasmissione...
Page 277 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà KIT.7006.0 Input shaft Right AE0.0018...
Page 278 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà KIT.7004 Assembled flange RIGHT AE0.0009...
Page 279 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà KIT.7015 Assembled flange RIGHT AE0.0009...
Page 280 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà KIT.7017 Assembled flange RIGHT AE0.0009...
Page 281 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà KIT.7019 Assembled flange RIGHT AE0.0009...
Page 282 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà KIT.7021 Assembled flange RIGHT AE0.0009...
Page 283 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà KIT.7012.0 Assembled casing KIT.7009.0 Scatola assemblata...
Page 284 Lista ricambi PMS701 HS-TR Spare parts STD version Lista ricambi: kit disponibili Tab. C Spare parts list: available kits Kit N° Ref. N° Designation Part N° Ref. N° Q.ty Kit-Nr Bestell-Nr Bezeichnung Teil-Nr Bestell-Nr M.ge Codice Descrizione Posiz. Codice Q.tà K7S.0525.0 Assembled right body 260.0047 Corpo DX assemblato...
Page 285 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD version Smontaggio Riduttore Gearbox disassembly -descrizione generale -general description Scaricare l’olio sia del gruppo freno che You have to drain the oil both from the del riduttore rimuovendo i tappi (76 e 78 brake disc chamber and from the reduction magnetico) nella parte inferiore e i tappi...
Page 286 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD version Smontaggio Albero Ingresso (1/2) Disassembly of the Input Shaft (1/2) Rimuovere il Seeger (45) e togliere l’albe- Remove first the retaining ring (45) and ro utilizzando un martello di gomma. using a rubber hammer take out the input Utilizzando un estrattore sfilare il cuscinet- shaft.
Page 287 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD version Smontaggio Corona Epicicloidale (6) e Disassembly of the Planet Crown (6) and of Mozzo (21) the Wheel Hub (21) Per estrarre i satelliti (30) preassemblati In order to pull out the planet gears (30) con i loro cuscinetti (54) rimuovere l’anello and their bearings (54), remove the retain- (38), quindi utilizzare un’estrattore idoneo...
Page 288 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD version Montaggio Riduttore Assembly of the Reduction Gear -descrizione generale -general description Dopo aver sostituito le parti usurate pro- After the worn-out parts have been re- cedere al montaggio eseguendo al contrario placed, to assemble the unit again follow the le operazioni svolte durante lo smontaggio.
Page 289 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD version Montaggio Corona Epicicloidale (6) e Assembling the Ring gear (6) and the Wheel Mozzo (21) Hub (21) Introdurre la coppa (anello esterno) dei Insert the cup (outer ring) of the conical cuscinetti conici (58) e (59) nelle rispettive bearings (58) and (59) in their front and sedi frontale e posteriore della scatola (31);...
Page 290 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD version Inserire il disco portacorona (19) nella Insert the ring-gear carrier disc (19) into corona (6) e bloccarlo inserendo la molla the ring gear (6) and fix it introducing the (68) nell'apposita sede (fig. 18a), quindi retaining ring (68) in its housing (fig.
Page 291 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD version Montaggio Albero Ingresso (1/2) Assembling the Input Shaft (1/2) Calettare il cuscinetto (56) sull' albero (1/2), Key the bearing (56) onto the input shaft inserire il tutto nella sede della flangia (1/2), insert it into the housing in the flange (16/17) e bloccare con l’anello Seeger (45) (16/17) and lock all with the retaining ring (fig.
Page 292 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD VERSION A questo punto è possibile rimontare il Now is possible to assemble the brake disc pacco freni rispettando scrupolosamente i unit paying attention to respect the steps on passi indicati a pag. 12. Completata questa page 12.
Page 293 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD version Specifiche di massima per la costruzione General specifications for the tool needed dell’attrezzo necessario per svitare (vedi to open (see page 41) and close (see page pag. 41) e riavvitare (vedi pag. 44) la ghiera 44) the ring nut (18).
Page 294 Disassemblaggio/assemblaggio PMS701 HS-TR Disassembly / assembly STD version Disassemblaggio corpo differenziale/ Disassembly the differential gear/tone ruota fonica wheel Dopo aver rimosso il gruppo freno + ridut- After the brake unit + reduction gearbox tore, scollegare i manicotti dell’impianto have been removed, disconnect the sleeves frenante di servizio e il cavo della leva fre- of the hydraulic service brake circuit and no positivo.
Page 295 Descrizione revisioni PMS701 HS-TR Revisions account STD version CRONOLOGIA REVISIONI / REVISIONS CHRONOLOGY Data di emissione/Date of issue 23/01/2008 I° revisione/revision II° revisione/revision III° revisione/revision IV° revisione/revision DESCRIZIONE REVISIONI / REVISIONS ACCOUNT I° revisione/revision II° revisione/revision III° revisione/revision IV° revisione/revision Questa pubblicazione annulla e sostituisce ogni This publication replaces and supersseds any previ- precedente edizione o revisione.
Page 296 PMS701 HS-TR PMS 700 brake STD version maintenance Pro-mec s.p.a. 33030 Coseano (Udine) Via dell’Industria, 2 Tel. +39 0432.863611 - Fax +39 0432.861333 www.pmp-promec.it E-mail comm@pmp-promec.it Reg imprese Ud n. 22586/1996 Cod. Fisc. e P. IVA 01924790304 Vers. PMS701 HS-TR STD version 23/01/08 Pag.
Page 297 Draft 11 July 2008 12 3 4 12 3 6 & 1238 AC INDUCTION MOTOR CONTROLLERS OS 11 with © 2008 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. 1234/36/38 Manual, p/n 37022 Rev.
Page 299 1 1 J U LY 2 0 0 8 D R A F T CONTENTS CONTENTS 1. OVERVIEW ................1 2. INSTALLATION AND WIRING..........3 Mounting the Controller .............3 High Current Connections and Wiring Guidelines....6 Low Current Connections and Wiring Guidelines....8 Controller Wiring: Basic Conﬁguration ......12 Switch Input Wiring ............13 Throttle Wiring ..............13 Input/Output Speciﬁcations..........18...
Page 300 1 1 J U LY 2 0 0 8 D R A F T FIGURES / TABLES FIGURES . 1: Curtis 1234, 1236, and 1238 controllers ......... 1 . 2a: Mounting dimensions, Curtis 1234 controller ......3 . 2b: Mounting dimensions, Curtis 1236/38 controllers ....4 .
Page 301: Overview
1 1 J U LY 2 0 0 8 D R A F T 1 — OVERVIEW OVERVIEW Curtis 1234, 1236, and 1238 AC induction motor controllers deliver smooth power unlike any previous vehicle control system. They provide unprecedented ﬂexibility and power through inclusion of a ﬁeld-programmable logic controller embedded in a state-of-the-art motor controller.
Page 302 1 1 J U LY 2 0 0 8 D R A F T 1 — OVERVIEW ✓ Adaptation of control algorithm to motor temperature variation so optimal performance is maintained under widely varying conditions ✓ Real-time battery current, motor torque, and power estimates available ✓...
Page 303: Installation And Wiring
1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING INSTALLATION AND WIRING MOUNTING THE CONTROLLER The outline and mounting hole dimensions for the 1234 controller are shown in Figure 2a, and for the 1236 and 1238 controllers in Figure 2b. These control- lers meet the IP65 requirements for environmental protection against dust and water.
Page 304 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING heatsink to the mounting surface. Additional heatsinking or fan cooling may be necessary to meet the desired continuous ratings. You will need to take steps during the design and development of your end product to ensure that its EMC performance complies with applicable regulations;...
Page 305 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING ☞ Working on electrical systems is potentially dangerous. You should C A U T I O N protect yourself against uncontrolled operation, high current arcs, and outgassing from lead acid batteries: —...
Page 306: Table 1 High Current Connections
1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: High Current Connections HIGH CURRENT CONNECTIONS There are ﬁve high-current terminals, identiﬁed on the controller housing as , and Table 1 High Current Connections TERMINAL FUNCTION Positive battery to controller.
Page 307 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: High Current Connections Lug assembly: 1236 and 1238 models Five brass M8 terminals are provided. Lugs should be installed as follows, using M8 bolts sized to provide proper engagement (see diagram): •...
Page 308: Table 2: Low Current Connections
1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Low Current Connections LOW CURRENT CONNECTIONS All low power connections are made through a single 35-pin AMPSEAL con- nector. The mating plug housing is AMP p/n 776164-1 and the contact pins are AMP p/n 770520-3.
Page 309 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Low Current Connections Table 2 Low Current Connections RELATED VCL NAME DESCRIPTION FUNCTIONS REFERENCES Keyswitch input. Setup_BDI Keyswitch_Voltage Provides logic power for the controller and power for the coil drivers.
Page 310 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Low Current Connections Table 2 Low Current Connections, cont’d RELATED VCL NAME DESCRIPTION FUNCTIONS REFERENCES 12 Switch 6 Generic switch input #6. Sw_6 13 Coil Return This is the coil return pin...
Page 311 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Low Current Connections Table 2 Low Current Connections, cont’d RELATED VCL NAME DESCRIPTION FUNCTIONS REFERENCES 28 Serial TX Serial transmit line for Setup_Serial display or ﬂash update.
Page 312: Controller Wiring: Basic Configuration
1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Standard Wiring Diagram CONTROLLER WIRING: BASIC CONFIGURATION A basic wiring diagram is shown in Figure 3. Throttle and brake are shown in the diagram as 3-wire potentiometers;...
Page 313: Switch Input Wiring
1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Throttle Wiring to check for welded or missing contactor faults and uses the main contactor coil driver output to remove power from the controller and motor in the event of various other faults.
Page 314 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Throttle Wiring For potentiometers, the controller provides complete throttle fault protection that meets all applicable EEC regulations. For voltage throttles, the controller protects against out-of-range wiper values, but does not detect wiring faults;...
Page 315 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Throttle Wiring Fig. 5 Wiring for Type 2 Voltage Source throttles. Current Source 3-wire Potentiometer Curtis ET-XXX Electronic Throttle Curtis 1234/36/38 Manual, Rev.
Page 316 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Throttle Wiring When a 3-wire potentiometer is used, the controller provides full fault protection in accordance with EEC requirements. The pot is used in its voltage divider mode, with the controller providing the voltage source and return.
Page 317 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: Throttle Wiring Throttle Type 5 Throttle Type 5 provides a different way of sending the throttle command to the controller. This throttle type uses VCL to deﬁne the throttle signal that will be “input”...
Page 318 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: I/O Signal Speciﬁcations INPUT/OUTPUT SIGNAL SPECIFICATIONS The input/output signals wired to the 35-pin connector can be grouped by type as follows; their electrical characteristics are discussed below. —...
Page 319 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: I/O Signal Speciﬁcations Low power outputs Two control lines on the 1236/38 are available as low power digital outputs. These are open collector drivers that can only sink current, not source it, and are intended to drive LEDs or other low current loads connected to the +5V or +12V external power supplies;...
Page 320 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: I/O Signal Speciﬁcations Analog inputs Two control lines can be used as analog inputs. Both inputs are protected against shorts to B+ or B-. Typically Analog 2 is used as the input for the motor temperature sensor.
Page 321 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: I/O Signal Speciﬁcations KSI and coil return KSI input provides power for all low power control circuits, power capacitor precharge (before main contactor turn on), power supply outputs, and high power output drivers.
Page 322 1 1 J U LY 2 0 0 8 D R A F T 2 — INSTALLATION & WIRING: I/O Signal Speciﬁcations Communications ports Separate CAN and serial ports provide complete communications and program- ming capability for all user available controller information. The Curtis 1311 handheld programmer plugs into a connector wired to pins 28 and 29, along with ground (pin 7) and the +12V power supply (pin 25);...
Page 323: Programmable Parameters
1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS PROGRAMMABLE PARAMETERS These controllers have a number of parameters that can be programmed using a Curtis 1311 handheld programmer or 1314 Programming Station. The pro- grammable parameters allow the vehicle’s performance to be customized to ﬁt the needs of speciﬁc applications.
Page 324: Table 3: Programmable Parameter Menus
1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS Table 3 Programmable Parameter Menus: 1311 Programmer CONTROL MODE SELECT ... p. 27 2 - TORQUE MODE MENU CURRENT LIMITS MENU ..... p. 39 —Drive Current Limit —Speed Limiter ....
Page 325 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS Table 3 Programmable Parameter Menus: 1311 Programmer, cont’d EM BRAKE CONTROL MENU..p. 46 MOTOR MENU ......p. 53 EMERGENCY REVERSE MENU ..p. 59 —Brake Type —Typical Max Speed —EMR Enable...
Page 326 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS Individual parameters are presented as follows in the menu charts: Parameter name Allowable range Description of the parameter’s as it appears in the in the function and, where applicable, programmer display...
Page 327 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Control Mode Select Parameter CONTROL MODE SELECT ALLOWABLE PARAMETER RANGE DESCRIPTION Control Mode Select 0–2 This parameter determines which control method will be in effect when Control_Mode_Select 0–2 programming motor response:...
Page 328 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Speed Controller Parameters (SPEED MODE EXPRESS) SPEED MODE EXPRESS MENU 0 – SPEED MODE EXPRESS ALLOWABLE PARAMETER RANGE DESCRIPTION Max Speed 100–8000 rpm Deﬁnes the maximum requested motor rpm at full throttle.
Page 329 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Speed Controller & Velocity Feedforward Parameters (SPEED MODE) SPEED CONTROLLER MENU 1 – SPEED MODE ALLOWABLE PARAMETER RANGE DESCRIPTION Max Speed 100–8000 rpm Deﬁnes the maximum requested motor rpm at full throttle.
Page 330 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Acceleration Feedforward Parameters (SPEED MODE) ACCELERATION FEEDFORWARD MENU 1 – SPEED MODE [OPTIONAL] ALLOWABLE PARAMETER RANGE DESCRIPTION Kaff 0–500 A This acceleration feedforward term is designed to improve throttle Kaff_SpdM 0–5000 responsiveness and speed controller performance at all speeds.
Page 331 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Response Parameters (SPEED MODE) RESPONSE MENU 1 – SPEED MODE ALLOWABLE PARAMETER RANGE DESCRIPTION Full Accel Rate HS 0.1–30.0 sec Sets the rate (in seconds) at which the speed command increases Full_Accel_Rate_HS_SpdM 100–30000 when full throttle is applied at high vehicle speeds.
Page 332: Fig. 7 Response Rate Diagram
1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Fine Tuning Parameters (SPEED MODE) FINE TUNING MENU 1 – SPEED MODE ALLOWABLE PARAMETER RANGE DESCRIPTION Partial Decel Rate 0.1–30.0 sec. Sets the rate (in seconds) that is used to slow down the vehicle Partial_Decel_Rate_SpdM 100–30000 when the throttle is reduced without being released to neutral.
Page 333 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Pump Enable Parameter (SPEED MODE) PUMP ENABLE 1 – SPEED MODE ALLOWABLE PARAMETER RANGE DESCRIPTION Pump Enable On/Off This parameter should be programmed On to operate a pump motor AC_Pump_Enable_SpdM On/Off rather than a vehicle drive motor.
Page 334 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Speed Limiter Parameters (TORQUE MODE) SPEED LIMITER MENU 2 – TORQUE MODE ALLOWABLE PARAMETER RANGE DESCRIPTION Max Speed 500–8000 rpm Deﬁnes the maximum allowed motor rpm for torque control mode Max_Speed_TrqM 500–8000 (independent of throttle position).
Page 335 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Response Parameters (TORQUE MODE) RESPONSE MENU 2 – TORQUE MODE ALLOWABLE PARAMETER RANGE DESCRIPTION Accel Rate 0.1–30.0 sec. Sets the rate (in seconds) at which the motor torque increases to full Accel_Rate_TrqM 100–30000 when full throttle is applied.
Page 336 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Fine Tuning Parameters (TORQUE MODE) FINE TUNING MENU 2 – TORQUE MODE ALLOWABLE PARAMETER RANGE DESCRIPTION Creep Torque 0–100 % Determines the amount of torque applied to the vehicle at a stop with Creep_Torque_TrqM 0–32767 no throttle input, to emulate the feel of an automatic transmission...
Page 337: Fig. 8 Throttle Mapping (Torque Control Mode)
1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Fine Tuning Parameters (TORQUE CONTROL MODE) Fig. 8 Throttle mapping (torque control mode). Fig. 9 Effect of Gear Soften parameter (torque control mode). TIME Fig.
Page 338 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Restraint and Position Hold Parameters RESTRAINT MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Restraint Forward 0–100 % Increases torque when on a steep hill in order to limit roll-forward speed. Restraint_Forward 0–32767 Setting this parameter too high may cause oscillations in the motor as it...
Page 339 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Current Limit Parameters POSITION HOLD MENU, cont’d ALLOWABLE PARAMETER RANGE DESCRIPTION Entry Rate 5–100 % When the vehicle transitions from forward speed to reverse speed Entry_Rate_Position_Hold 50–1000 or from reverse speed to forward speed (for example, when coming to...
Page 340: Fig . 11: Drive Current Limiting Map
1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Power & Drive Limiting Map Parameters POWER LIMITING MAP MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Nominal Speed 100–4000 rpm Sets the base speed that will be used in the drive limiting map and PL_Nominal_Speed 100–4000 regen limiting map.
Page 341: Fig . 12: Regen Current Limiting Map
1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Regen Limiting Map Parameters REGEN LIMITING MAP MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Nominal 0–100 % Sets PL_Regen_Nominal 0–32767 Plus Delta 0–100 % Sets These parameters deﬁne the percentage of regen current limit PL_Regen_Nominal_Plus_Delta...
Page 342 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Throttle Parameters THROTTLE MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Throttle Type 1–5 The 1234/36/38 controllers accept a variety of throttle inputs. The throttle Throttle_Type 1–5 type parameter can be programmed as follows:...
Page 343 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Throttle Parameters THROTTLE MENU, cont’d ALLOWABLE PARAMETER RANGE DESCRIPTION Reverse Deadband 0–5.00 V Reverse_Deadband 0–32767 Reverse Map 0–100 % Reverse_Map 0–32767 The four Throttle Reverse parameters are the same as their Throttle Forward counterparts, and apply when the throttle Reverse Max 0–5.00 V...
Page 344 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Throttle Parameters THROTTLE MENU, cont’d THROTTLE MENU, cont’d ALLOWABLE ALLOWABLE PARAMETER PARAMETER RANGE RANGE DESCRIPTION DESCRIPTION HPD/SRO Type 0–3 Determines whether the HPD/SRO feature will be active. One type of checks HPD_SRO_Type 0–3 is available for material-handling vehicles, and two types for golf-style vehicles.
Page 345 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Brake Parameters BRAKE MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Brake Pedal Enable On/Off Determines whether the brake input and algorithm are enabled, making Brake_Pedal_Enable On/Off the brake throttle part of the motor control command.
Page 346 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: EM Brake Control Parameters EM BRAKE CONTROL MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Brake Type 0–2 The brake type parameter determines how the EM brake responds to the EM_Brake_Type 0–2 interlock input, throttle, and vehicle motor speed.
Page 347 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: EM Brake Control Parameters EM BRAKE CONTROL MENU, cont’d ALLOWABLE PARAMETER RANGE DESCRIPTION Set Speed Threshold 5–100 rpm Determines the speed below which the EM brake will be commanded Set_Speed_Threshold 5–100 to set.
Page 348 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Main Contactor Parameters MAIN CONTACTOR MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Main Enable On/Off When programmed On, the controller’s native software controls the main Main_Enable On/Off contactor when the interlock is enabled;...
Page 349 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Main Contactor Parameters MAIN CONTACTOR MENU, cont’d ALLOWABLE PARAMETER RANGE DESCRIPTION Main DNC Threshold 0–84.0 V When Checks Enable = On, this parameter is used as the threshold for Main_DNC_Threshold 0–5376 detecting a Main Did Not Close fault.
Page 350 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Proportional Driver Parameters PROPORTIONAL DRIVER MENU ALLOWABLE PARAMETER RANGE DESCRIPTION PD Enable On/Off Determines how the PWM of the proportional driver is controlled. PD_Enable On/Off When programmed On, it is controlled by the controller’s PD current control...
Page 351 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Hydraulic Contactor Parameters HYDRAULIC CONTACTOR MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Contactor Enable On/Off When programmed On, VCL functions control Driver 3 as the hydraulic Hydraulic_Contactor_Enable On/Off pump contactor.
Page 352 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Fault Checking Parameters FAULT CHECKING MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Driver1 Checks Enable On/Off Driver1_Checks_Enable On/Off OptionBits2 [Bit 1] The ﬁve Checks Enable parameters are used to enable driver Driver2 Checks Enable and coil fault detection at the ﬁve individual drivers (at Pins On/Off...
Page 353 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Motor Parameters MOTOR MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Typical Max Speed 500–8000 rpm Set this parameter to the typical maximum motor speed of the vehicle. Typical_Max_Speed 500–8000 This value does not need to be set precisely;...
Page 354 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Motor Temperature Parameters MOTOR TEMPERATURE CONTROL MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Sensor Enable On/Off When programmed On, the motor temperature cutback and the motor MotorTemp_Sensor_Enable On/Off temperature compensation features are enabled.
Page 355 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Battery Parameters BATTERY MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Nominal Voltage 24–84 V Must be set to the vehicle’s nominal battery pack voltage. This parameter Nominal_Voltage 1536–5376 is used in determining the overvoltage and undervoltage protection thresholds...
Page 356 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Battery Parameters BATTERY MENU, cont’d ALLOWABLE PARAMETER RANGE DESCRIPTION User Undervoltage 50–80 % The value of this parameter is a percentage of the Nominal Voltage setting. User_Undervoltage 128–204 The User Undervoltage parameter can be used to adjust the undervoltage...
Page 357 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Battery Parameters BATTERY MENU, cont’d ALLOWABLE PARAMETER RANGE DESCRIPTION Reset Volts Per Cell 0.90–3.00 V The reset voltage level is checked only once, when KSI is ﬁrst turned on. BDI_Reset_Volts_Per_Cell 900–3000 Note that the BDI Reset Percent parameter also inﬂuences the algorithm...
Page 358 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Vehicle Parameters VEHICLE MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Metric Units On/Off When this parameter is programmed On, the distance variables (Vehicle Metric_Units On/Off Odometer, Braking Distance Captured, Distance Since Stop, Distance Fine, OptionBits3 [Bit 5]...
Page 359 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Emergency Reverse Parameters EMERGENCY REVERSE MENU [SPEED MODE & SPEED MODE EXPRESS only] ALLOWABLE PARAMETER RANGE DESCRIPTION EMR Enable On/Off Determines whether the emergency reverse function is active. EMR_Enable On/Off On = emergency reverse is enabled.
Page 360 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Interlock Braking Parameters INTERLOCK BRAKING MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Enable On/Off Determines whether the interlock braking function is active. Interlock_Brake_Enable On/Off On = The controller will attempt to bring the vehicle to a stop using regen OptionBits3 [Bit 7] braking when the interlock signal is removed.
Page 361 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: CAN Interface Parameters CAN INTERFACE MENU ALLOWABLE PARAMETER RANGE DESCRIPTION CANopen Interlock On/Off When programmed On, CAN NMT State must = 5 (operational state) »...
Page 362 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Field Weakening Control and Motor Type Parameters MOTOR CHARACTERIZATION TESTS MENU ALLOWABLE PARAMETER RANGE DESCRIPTION Contact your Curtis customer support engineer if you will be running the motor characterization tests yourself.
Page 363 1 1 J U LY 2 0 0 8 D R A F T 3 — PROGRAMMABLE PARAMETERS: Controiller Cloning CLONING (for copying parameter settings to multiple controllers) Once a controller has been programmed to the desired settings, these settings can be transferred as a group to other controllers, thus creating a family of “clone”...
Page 364: 4A. Monitor Menu
1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU MONITOR MENU Through its Monitor menu, the 1311 programmer MONITOR MENU provides access to real-time data during vehicle —Inputs....p. 64 operation. This information is helpful during —Outputs ....
Page 365 1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU Monitor Menu: INPUTS, cont’d DISPLAY VARIABLE RANGE DESCRIPTION Emer Rev On/Off Emergency reverse input on or off. The EMR_State On/Off source of the emergency reverse input is System_Flags1 [Bit 1] determined by the EMR Type parameter: from Switch 1 (pin 24) if EMR Type = 0...
Page 366 1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU Monitor Menu: INPUTS, cont’d DISPLAY VARIABLE RANGE DESCRIPTION Driver 3 Input On/Off Driver 3 input on or off (pin 4). Sw_11 On/Off Switches [Bit 10] Driver 4 Input On/Off...
Page 367 1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU Monitor Menu: OUTPUTS DISPLAY VARIABLE RANGE DESCRIPTION Analog Out 0–10.0 V Voltage at Analog output (pin 30). Analog_Output 0–32767 Digital Out 6 On/Off Digital Out 6 output on or off (pin 19).
Page 368 1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU Monitor Menu: BATTERY DISPLAY VARIABLE RANGE DESCRIPTION 0–100 % Battery state of charge. BDI_Percentage 0–100 Capacitor Voltage 0–105 V Voltage of controller’s internal capacitor bank Capacitor_Voltage 0–6720 at B+ terminal.
Page 369 1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU Monitor Menu: CONTROLLER DISPLAY VARIABLE RANGE DESCRIPTION Current (RMS) 0–1000 A RMS current of the controller, taking all Current_RMS 0–10000 three phases into account. Modulation Depth 0–100 % Percentage of available voltage being used.
Page 370 1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU Monitor Menu: CUTBACKS DISPLAY VARIABLE RANGE DESCRIPTION Motor Temp Cutback 0–100 % Displays the current available as a result of MotorTempCutback 0–4096 the motor temperature cutback function.
Page 371 1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU ☞ Note: All vehicle Monitor Menu: VEHICLE calculations assume DISPLAY no tire slippage. VARIABLE RANGE DESCRIPTION Vehicle Speed -327.7–327.7 Vehicle speed, in units of MPH or KPH, Vehicle_Speed -32768–32767 depending on the setting of the Metric...
Page 372 1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU Monitor Menu: VEHICLE, cont’d DISPLAY VARIABLE RANGE DESCRIPTION Time to Dist 3 0–128 sec Time taken for the vehicle to travel from Time_to_Capture_Dist_3 0–32000 zero rpm to the programmed Capture...
Page 373 1 1 J U LY 2 0 0 8 D R A F T 4a — MONITOR MENU Monitor Menu: CAN STATUS DISPLAY VARIABLE RANGE DESCRIPTION CAN NMT State 0–127 Controller CAN NMT state: CAN_NMT_State 0–127 0=initialization, 4=stopped, 5=operational, 127=pre-operational. PDO1 MOSI Byte Map* 0 –...
Page 374: 4B. Controller Information Menu
1 1 J U LY 2 0 0 8 D R A F T 4b — CONTROLLER INFO MENU CONTROLLER INFORMATION MENU This menu provides ID and version numbers for your controller hardware and software. CONTROLLER INFORMATION MENU DISPLAY VARIABLE RANGE DESCRIPTION Model Number...
Page 375: Initial Setup
1 1 J U LY 2 0 0 8 D R A F T 5 — INITIAL SETUP INITIAL SETUP The 1234/36/38 controllers can be used in a variety of vehicles, which differ widely in characteristics. Before driving the vehicle, it is imperative that these initial setup procedures be carefully followed to ensure that the controller is set up to be compatible with your application.
Page 376 1 1 J U LY 2 0 0 8 D R A F T 5 — INITIAL SETUP the AC Motor Characterization Procedure is used, it can determine the encoder steps (but only for encoders with 32, 64, or 80 ppm). ☞...
Page 377 1 1 J U LY 2 0 0 8 D R A F T 5 — INITIAL SETUP support engineer to resolve any issues about the interlock before continuing with the setup procedure. Once you have veriﬁed the interlock is off, you can set up the throttle input.
Page 378 1 1 J U LY 2 0 0 8 D R A F T 5 — INITIAL SETUP neutral. The displayed Mapped Brake should be = 100% through the range of motion that is considered max. Contact your Curtis customer support engineer to resolve any issues about the brake setup before continuing with the setup procedure.
Page 379 1 1 J U LY 2 0 0 8 D R A F T 5 — INITIAL SETUP the direction input. If the motor is turning in the correct direction but appears to be “ﬁghting itself ” (struggling at full current while jerkily turning at very low speed), change the setting of the Swap Encoder Direction parameter.
Page 380: Tuning Guide
1 1 J U LY 2 0 0 8 D R A F T 6 — TUNING GUIDE TUNING GUIDE Many aspects of vehicle performance can be optimized, using the wide variety of adjustable parameters available to the 1234/36/38 controllers. Once a ve- hicle/motor/controller combination has been tuned, the parameter values can be made standard for the system or vehicle model.
Page 381 1 1 J U LY 2 0 0 8 D R A F T 6 — TUNING GUIDE Speed parameter you should not readjust it without adjusting all the rate parameters as well. d. Kp and Ki typically do not need to be changed as the default values will work well in most applications.
Page 382 1 1 J U LY 2 0 0 8 D R A F T 6 — TUNING GUIDE d. Kp typically does not need to be changed as the default value will work well in most applications. This parameter controls how tightly the ac- tual motor speed will track the requested speed trajectory (speed trajec- tory is set by the accel, decel, and brake rates).
Page 383 1 1 J U LY 2 0 0 8 D R A F T 6 — TUNING GUIDE f. In the Speed Mode» Response menu, adjust the remaining three brake rate parameters as necessary while reversing the throttle input (i.e., full throttle forward to low throttle reverse, full throttle forward to full throttle reverse, full throttle reverse to low throttle forward, etc.).
Page 384: Vehicle Control Language
1 1 J U LY 2 0 0 8 D R A F T 7 — VCL VEHICLE CONTROL LANGUAGE (VCL) Curtis 1234/36/38 AC induction controllers have a built-in programmable logic controller with application-speciﬁc functions. VCL (Vehicle Control Language) software provides a way to implement unique and complex vehicle control functions.
Page 385 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL The VCL functions described in the VCL Common Functions Manual are available on 1234/36/38 controllers. These controllers also have these addi- tional functions: ENABLE_PRECHARGE()....
Page 386 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL are typically written to EEPROM through the 1311 programmer interface (i.e., when a 1311 user changes a parameter setting using the 1311). They can be used in the VCL code, but changing a P_User (or P_UserBit) value with VCL will only change the variable value in RAM and will not change the value in EEPROM.
Page 387 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL VCL RUNTIME RATES VCL is an interpreted language. Each line of VCL code is converted (compiled) into a set of codes and then ﬂash loaded into the controller. The controller interprets these codes one line at a time while the system is powered up.
Page 388 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL (Sw_1 = ON) ;put code here to run when switch 1 is On if (Sw_16 = OFF) ;put code here to run when switch 16 is Off All switch inputs are automatically debounced by the VCL operating system.
Page 389 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL Set_DigOut(DigOut6) will set Digital Output 6 On (active). VCL can monitor the present value of a digital output driver: the bit variable Digx_Output (where “x” is the digital output channel number) is automatically ﬁlled with the present value of the driver output (On or Off ).
Page 390 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL To set up the brake pot input for use in VCL, use the Brake_Pot constant in place of the Thottle_Pot constant in the Setup_Pot function. Setup_Pot(BRAKE_POT,TWO_WIRE) will set up the brake pot input for wiring using two connections (pins 17, 18).
Page 391 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL AnalogOut uses the same Put_PWM() and Automate_PWM() used by these other drivers. The scaling is 0–10V = 0–32767. Put_PWM(PWM6,6553) will generate 2.0 volts at the analog output. VCL can monitor this output using the variable Analog_Output.
Page 392 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL Curtis 1234/36/38 Manual, Rev. D...
Page 393 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL This allows the VCL to either multiply (Throttle_Multiplier > 128) or divide (Throttle_Multiplier < 128) the nominal throttle value. Typically the default multiplier is set to 128, thus having no net effect. Both Throttle_Multiplier and Throttle_Offset can be positive or negative.
Page 394 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL Brake Processing Brake processing is optional as it can be turned Off (by setting Brake_Pedal_En- able = Off, see page 45). If turned On, brake processing can be done with or without VCL.
Page 395 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL The following brake processing variables are accessible by VCL: VCL VARIABLE ACCESS DESCRIPTION Pot2_Raw Read Only Voltage measurement at pin 17 Brake_Pot_Output Read Only Brake pot input value after being scaled for the proper wiring OS_Brake...
Page 396 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL Curtis 1234/36/38 Manual, Rev. D...
Page 397 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL Fig. 16 Proportional driver processing. function. Note that Mapped_Throttle is inverted; lowering its value (making it more negative) increases the PD_Throttle value. The Dither function adds and subtracts from the current command to the PD based on PD_Dither_Percent, at a rate set by PD_Dither_Period.
Page 398 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL USING THE FAULT HANDLER IN VCL The operating system of the controller detects various faults and takes appropri- ate fault actions to protect the controller. These faults have fault codes that are ﬂashed on the controller status LEDs, and fault text is displayed in the 1311 System Faults and Fault History menus.
Page 399 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL Status5 Bit0 = External Supply Out of Range (Code 69) Bit1 = Motor Temp Sensor Fault (Code 29) Bit2 = VCL Run Time Error (Code 68) Bit3 = +5V Supply Failure (Code 25) Bit4 = OS General (Code 71) Bit5 = PDO Timeout (Code 72)
Page 400 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL The operating system also provides the capability to create OEM-deﬁned custom faults using VCL. Just as with system faults, the VCL fault codes are ﬂashed on the controller Status LEDs and fault text is displayed on the 1311 System Faults and Fault History menus.
Page 401 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL To add automatic fault actions to the VCL faults, the VCL program- mer must deﬁne the desired fault actions by using the sixteen VCL variables: User_Fault_Action_01 through User_Fault_Action_16.
Page 402 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL addition to ﬂashing the code 52 on the controller status LEDs. An additional VCL line was added (Put_Spy_Text (“BDI Low”)) to show how additional ac- tions beyond those provided in the User_Fault_Action_xx can be programmed using VCL.
Page 403 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL VCL FUNCTIONS SPECIFIC TO 1234/36/38 AC CONTROLLERS Function descriptions are provided here for the functions that are unique to these controllers. They are presented in the same format that is used in the VCL Common Functions Manual for the common functions.
Page 404 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL DISABLE_PRECHARGE() This function is designed to abort the precharge function and clear any precharge fault. This function aborts the request for precharge of the capacitor bank from KSI. The resultant state of the precharge variable (Precharge_State) will be set to = 3 (for precharge aborted).
Page 405 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL SET_DIGOUT() This function turns on the selected digital output. The digital outputs are active low (On = driver on and pulled to ground, Off = open circuit at the pin). The low power digital output is protected from excessive current (current over 15 mA);...
Page 406 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL ENABLE_EMER_REV() This function is used to engage emergency reverse using VCL. The 1311 EMR Type must be set to = 1 in order for the Enable_Emer_Rev() function to operate. If the system emergency reverse state is enabled (EMR_State bit variable = On), the emergency reverse function will operate according to the Emergency Reverse parameter settings;...
Page 407 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL SET_INTERLOCK() This function is used to engage the system interlock using VCL. The 1311 Interlock Type parameter must be set to = 1 in order for the Set_Interlock() function to operate. If the system interlock is set (Interlock_State bit variable = On), the throttle input signal is allowed to pass along the throttle chain;...
Page 408 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL SETUP_POT_FAULTS() This function sets the upper and lower wiper fault voltages for a given pot input and sets the replacement wiper voltage value that will be used if there is a fault. The valid range for the function parameters is 0–6.25 V (0–400 counts).
Page 409 1 1 J U LY 2 0 0 8 D R A F T 7 — VCL START_PUMP() This function is used to turn on the pump lift contactor. If the 1311 parameter » » Drivers Hydraulic Contactor Contactor Enable = On (VCL HydraulicContactorEnable bit variable = On), the VCL function Start_Pump() will turn on the pump lift contactor (Driver 3).
Page 410: Diagnostics And Troubleshooting
1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING These controllers detect a wide variety of faults or error conditions. Faults can be detected by the operating system or by the VCL code. This section describes the faults detected by the operating system.
Page 411: Table 4 Types Of Led Display
1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING Summary of LED display formats The two LEDs have four different display modes, indicating the type of infor- mation they are providing. Table 4 TYPES OF LED DISPLAY DISPLAY STATUS...
Page 412: Table 5 Troubleshooting Chart
1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Controller Overcurrent 1. External short of phase U,V, or W Set: Phase current exceeded the current motor connections.
Page 413 1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Severe Overvoltage 1. See Monitor menu » Battery: Set: Capacitor bank voltage exceeded Capacitor Voltage.
Page 414 1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Digital Out 7 Overcurrent 1. External load impedance on Digital Set: Digital Output 7 (pin 20) current Output 7 driver (pin 20) is too low.
Page 415 1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT PD Open/Short 1. Open or short on driver load. Set: Proportional driver (pin 2) is either 2.
Page 416 1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Pot2 Wiper Low 1. See Monitor menu » Inputs: Set: Pot2 wiper (pin 17) voltage Pot2 Raw.
Page 417 1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT VCL Run Time Error 1. VCL code encountered a runtime Set: Runtime VCL code error condition.
Page 418 1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Motor Characterization Fault 1. Motor characterization failed during Set: Motor characterization failed during characterization process.
Page 419 1 1 J U LY 2 0 0 8 D R A F T 8 — DIAGNOSTICS & TROUBLESHOOTING Table 5 TROUBLESHOOTING CHART, continued PROGRAMMER LCD DISPLAY CODE POSSIBLE CAUSE SET/CLEAR CONDITIONS EFFECT OF FAULT Emer Rev Timeout 1. Emergency Reverse was activated Set: Emergency Reverse was activated and and concluded because the EMR ran until the EMR Timeout timer expired.
Page 420: Maintenance
1 1 J U LY 2 0 0 8 D R A F T 9 — MAINTENANCE MAINTENANCE There are no user serviceable parts in Curtis 1234/36/38 controllers. No attempt should be made to open, repair, or otherwise modify the controller. Doing so may damage the controller and will void the warranty.
Page 421: Appendix A Theory Of Operation
1 1 J U LY 2 0 0 8 D R A F T APPENDIX A: THEORY OF OPERATION APPENDIX A THEORY OF OPERATION Curtis 1234/36/38 controllers convert DC battery power to 3-phase AC power by precisely controlling the induction drive for high bandwidth, high efﬁciency, and low ripple torque generation.
Page 422 1 1 J U LY 2 0 0 8 D R A F T APPENDIX A: THEORY OF OPERATION to provide better control. The mathematical model of an induction motor is complex. Using a series of reference frame transformations, vector control simpliﬁes the model to enable precise control of torque and ﬂux, similar to a SepEx motor controller.
Page 423: Fig . A-2: Power Section Topology
1 1 J U LY 2 0 0 8 D R A F T APPENDIX A: THEORY OF OPERATION Fig. A-2 Power section topology. Heavy busbars connect the IMS modules to the external motor connec- tion studs. A bank of power capacitors keeps DC bus levels stable during high frequency MOSFET switching and also reduces EMI on the external B+ and B- cables.
Page 424 1 1 J U LY 2 0 0 8 D R A F T APPENDIX B: EMC & ESD DESIGN CONSIDERATIONS APPENDIX B VEHICLE DESIGN CONSIDERATIONS REGARDING ELECTROMAGNETIC COMPATIBILITY (EMC) AND ELECTROSTATIC DISCHARGE (ESD) ELECTROMAGNETIC COMPATIBILITY (EMC) Electromagnetic compatibility (EMC) encompasses two areas: emissions and immunity.
Page 425 1 1 J U LY 2 0 0 8 D R A F T APPENDIX B: EMC & ESD DESIGN CONSIDERATIONS Conducted paths are created by the wires connected to the controller. These wires act as antennas and the amount of RF energy coupled into them is generally proportional to their length.
Page 426 1 1 J U LY 2 0 0 8 D R A F T APPENDIX B: EMC & ESD DESIGN CONSIDERATIONS Given the safety considerations involved in connecting electrical components to the chassis or frame in battery powered vehicles, such ﬁltering will usually consist of a series inductor (or ferrite bead) rather than a shunt capacitor.
Page 427 1 1 J U LY 2 0 0 8 D R A F T APPENDIX C: PROGRAMMER OPERATION APPENDIX C PROGRAMMERS Curtis programmers provide programming, diagnostic, and test capabilities for 1234/36/38 controllers. The power for operating the programmer is supplied by the host controller via a 4-pin connector.
Page 428 1 1 J U LY 2 0 0 8 D R A F T APPENDIX C: PROGRAMMER OPERATION information from the controller. For experimenting with settings, the program- mer can be left plugged in while the vehicle is driven. The bookmark keys can make parameter adjustment more convenient. To set a bookmark, press one of the three bookmark keys for more than two seconds.
Page 429 1 1 J U LY 2 0 0 8 D R A F T APPENDIX D: SPECIFICATIONS APPENDIX D SPECIFICATIONS Table D-1 SPECIFICATIONS: 1234/36/38 CONTROLLERS Nominal input voltage 24V, 24 –36V, 36–48V, 48–80V PWM operating frequency 10 kHz Maximum encoder frequency 15 kHz Maximum controller output frequency 300 Hz...
Page 431 M M A A N N U U A A L L 1 3 1 1 H A N D H E L D P R O G R A M M E R...
Page 432 CONTENTS 1. INTRODUCTION ..........1 1.1 Features ............1 1.2 Model Variants ..........2 1.3 Specifications ..........2 2. OVERVIEW ............3 2.1 Display Screen ..........4 2.2 Menu Navigation Key........4 2.3 Data Inc/Dec Key ..........4 2.4 Bookmark Keys..........4 3. OPERATION ............5 3.1 Menu Structure ..........5 3.2 Main Menu ............7 3.3 Interface Protocols &...
Page 433: Introduction
INTRODUCTION The Curtis Model 1311 Handheld Programmer simplifies pro- gramming, testing and diagnosing Curtis Speed Controllers and Auxiliary Devices. It provides a simple and intuitive interface to Curtis products for testing, diagnostics and para- meter adjustments. 1.1 Features • Compatible with Curtis speed controllers and auxiliary devices.
Page 434: 1.2 Model Variants
1.2 Model Variants Model 1311 Handheld Programmer is offered in four access level models: • 1311-1101 User programmer (most restrictive programmer; limited view into the system and a limited number of parameters and operations) • 1311-2201 Service programmer • 1311-3301 Dealer programmer •...
Page 435: Overview
OVERVIEW DISPLAY SCREEN MENU DATA NAVIGATION INC/DEC BOOKMARK KEYS page 3 Curtis 1311 Manual...
Page 436: 2.2 Menu Navigation Key
2.1 Display Screen A 128 x 64 pixel graphic LCD screen capable of displaying up to seven lines of text and graphic images simultaneously. 2.2 Menu Navigation Key Moves the screen cursor up or down through the Menu list (top or bottom arrow), and opens or closes Sub Menus (right and left arrows).
Page 437: Operation
OPERATION 3.1 Menu Structure After the data is uploaded from the unit (controller, charger, etc), the Main Menu appears. This is the standard Menu for all Curtis products and the starting point for all basic programmer functions. If there are no entries within a Menu, then that Menu title (Program, Monitor etc) will not be displayed.
Page 438 Entering a Main Menu (right arrow on the Menu Navigation Key) brings up a Sub-Menu, displayed in a second column and indented right. Program Max Speed Acceleration 1.2s Monitor Faults Functions Information Programmer Setup From the Program Menu you can go one additional SubMenu deeper into the detail screen.
Page 439: 3.2 Main Menu
3.2 Main Menu The Main Menu is the starting point for all Curtis programma- ble products. All basic functions are readily accessed from this point. Program The Program Menu may contain several Sub-Menus of parame- ters. The unit (controller, charger, display, etc) is setup with specific operating conditions using the 1311 handheld program- mer in this Menu.
Page 440: Interface Protocols & Backward Compatibility
3.3 Interface Protocols and backward compatibility Model 1311 has several protocols to communicate with other Curtis products. It automatically detects the correct protocol and begins the data upload immediately upon power up. (It is critical that the correct cable is used). Model 1311 Handheld Programmer also emulates the communication of the 1307 handheld programmer.
Page 441: 3.5 Real-Time Monitoring
When a parameter is displayed, its value and units (abbreviat- ed) will be displayed on the right of the screen. You can change the value of the parameter by using the Data Inc/Dec Key. Alternately, you can press the right arrow Menu Navigation Key once more and enter the detail screen (see section 3.1 Menu Structure for more details).
Page 442: Reading Faults And The Diagnostic History File
3.6 Reading Faults and the Diagnostic History file Model 1311 allows access to the present and past status of the system or unit you are connected to. Each Curtis product runs continuous self-diagnostics and will record and log an error event in non-volatile memory. When the 1311 is con- nected to the unit, this log file is automatically uploaded into the handheld programmer.
Page 443: Cloning And Restoring Previous Programming
3.7 Cloning and restoring the previous programming Cloning is the process of duplicating parameter settings from one unit to others, making copies or "clones". You may only clone units with the same hardware, software and parameter block. You cannot clone the MC-2 or products using the MCP protocol.
Page 444 3.8 Information Displays Besides the parameters, values and fault history, each Curtis product contains a small file describing the basic revision level of the product. The Information Menu provides access to that data. To view the product information, use the Menu Navigation Key to select 'Information' in the Main Menu (remember to press the right arrow to select a Menu).
Page 445 CURTIS INSTRUMENTS, INC. 200 Kisco Avenue, MT Kisco, NY 10549 Tel: (914) 666-2971 • FAX (914) 666-2188 is a registered trademark of Curtis Instruments, Inc. Specifications subject to change without notice © 2003 CURTIS INSTRUMENTS, INC. 53028 REV C 2/03...

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