Motrec E-500 Operator And Maintenance Manual
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Motrec E-500 Operator And Maintenance Manual

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E-500
OPERATOR AND MAINTENANCE MANUAL
SPARE PARTS LISTS INCLUDED
SERIAL NUMBER : 0900000 & UP
Printed in Canada

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Summary of Contents for Motrec E-500

  • Page 1 E-500 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER : 0900000 & UP Printed in Canada...
  • Page 2 To initiate warranty coverage on any MOTREC vehicle, the Dealer must complete and return the “Sales/Installation Report” to MOTREC within 30 days after delivery to the Original Retail Purchaser; or within 90 days after the delivery date to the Dealer, which ever occurs first. Failure to follow these procedures will result in considering the warranty coverage effective as of the shipment date from the factory.

  • Page 3: Table Of Contents

    ELECTRICAL TROUBLESHOOTING CURTIS SPEED CONTROLLER WIRING : STANDARD CONFIGURATION DIAGNOSTICS AND TROUBLESHOOTING TROUBLESHOOTING CHART LED DIAGNOSTICS PROGRAMMING PARAMETERS – E-290HD, E-348, E-480, E-500, E-660, T-248, T-448 CURTIS PMC MOTOR CONTROLLER OVERVIEW WIRING : STANDARD CONFIGURATION MAINTENANCE AND ADJUSTMENT SPARE PARTS...

  • Page 4: Instructions

    Instructions INSTRUCTIONS - 4 -...

  • Page 5: Safety Warnings For Operators

    Instructions SAFETY WARNINGS FOR OPERATORS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAY RESULT IN SEVERE INJURY. It is the responsibility of the owner of this vehicle to train operators to ensure that they understand the operating characteristics of this vehicle, including training in vehicle stability, and obey the following safety rules and guidelines.

  • Page 6: Operating Instructions

    Instructions OPERATING INSTRUCTIONS It is the responsibility of the owner of this vehicle to ensure that the operator understands the operating characteristics of this vehicle, and obeys the safety instructions in this manual and ANSI/ITSDF B56.8 & 9 Standards. Do not drive this vehicle unless you are a certified operator as required by OSHA. BEFORE TURNING ON KEYSWITCH Set to neutral, set parking brake, check for visible damage, check brake pedal.

  • Page 7: Maintenance

    Maintenance MAINTENANCE - 7 -...

  • Page 8: Safety Warnings For Service Technicians

    Maintenance SAFETY WARNINGS FOR SERVICE TECHNICIANS FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY. Owner shall comply with OSHA and ANSI/ITSDF B56.8 & B56.9 Standards for vehicle maintenance. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect carriers, vehicles, tractors, and batteries.
  • Page 9 Maintenance Do not try to increase motor speed by changing parameter settings in the speed controller; it can cause accident and severe damage to the motor. SEPEX speed controls are protected by a diode in the power circuit to filter inductive loads in the event of a sudden power interrupt.

  • Page 10: Decals And Labels

    Maintenance DECALS AND LABELS ! CAUTION ! The images included in this section depict the decals/markings installed on the vehicle. It is of the utmost importance that theses decals/markings remain unaltered and readable. Else, the sticker or the part baring the marking has to be replaced. Dashboard security warning label: General security warning label: # 5100000002...

  • Page 11: Periodic Maintenance Checklist

    Maintenance PERIODIC MAINTENANCE CHECKLIST REVISION 080206 ! WARNING ! Maintenance operations must be made by properly trained service technicians. Keep clear from moving parts such as tires, sheaves and motor. Check for all EE protections, when applicable, and keep cables and wires clear from mechanical and rubbing action Batteries contain sulphur acid that can cause severe burns on skin or eyes.

  • Page 12: Accelerator

    Maintenance ACCELERATOR GEAR Remove the cover. Backlash between gears must be reduced to a minimum by sliding holder; use locktite 262 to lock the three screws. When the plastic gear is fully depressed a small backlash must remain between the gears. When the plastic gear is released its rear portion must not exceed the pedal case.

  • Page 13: Belt Installation And Tensioning

    Maintenance BELT INSTALLATION AND TENSIONING INSTALLATION Adjust the sprockets using a straight edge. Slide up the edge on the larger pulley until it contacts the smaller pulley. Properly adjusted pulleys will provide three points of contact. Properly aligned pulleys will provide four points of contact. Tighten setscrews and recheck alignment. TENSIONING Check the force F required to provide a deflection of 1/8 in.

  • Page 14: Hydraulic & Parking Brakes

    Maintenance HYDRAULIC & PARKING BRAKES Revision 2008-02-06 DRUM BRAKES Remove brake drums and check lining wear. Replace shoes and springs if the lining thickness is 1/16" (2mm) or less. Turn the brake adjustment to reduce the clearance between lining and drum. Wheels must turn free when the pedal is released.

  • Page 15: Front Axle And Steering

    Maintenance FRONT AXLE AND STEERING ! CAUTION ! Before maintenance, turn off all switches, set to neutral, set parking brake, remove the key, and raise the front end of the vehicle supporting it with two jack stands of adequate capacity STEERING INSPECTION Check tire inflation pressure, suspension components, tie rods straightness, tie rod ends play (wear), play (wear) in wheel bearings, kingpins and bushings.

  • Page 16: Battery Maintenance

    Maintenance BATTERY MAINTENANCE ! WARNING ! It is the responsibility of the owner of this vehicle to ensure that the service technicians are properly trained, read and obey the safety rules and guidelines in this manual (ANSI B56). Maintenance operations must be made by properly trained service technicians only. Before any maintenance work, park the vehicle on a flat level surface, turn off all the switches, set to neutral, remove the key, lift the wheels off the ground and secure with jack stands of adequate capacity.
  • Page 17 Maintenance BATTERY MOUNTING A loose battery increases damaging effects of vibrations and is more prone to short out. BATTERY DISCHARGE LIMIT Discharging below a 20% state of charge cuts down the battery life and the number of cycles available. At 20% state of charge, specific gravity of 6V battery should be 1180; and 1220 for industrial battery. CHARGING AREA Always charge battery in a well ventilated area set for and approved for charging.

  • Page 18: Battery Charger

    Maintenance BATTERY CHARGER ! WARNING ! Always unplug the AC and DC electrical cords before attempting any repairs to the charger. CHARGER DOES NOT TURN ON: Dc cord of portable chargers must be disconnected from batteries after every charge to restart; Check dc fuse links;...

  • Page 19: Electrical Troubleshooting

    Maintenance ELECTRICAL TROUBLESHOOTING ! WARNING ! Maintenance work must be performed by trained service technicians only. It is the responsibility of the owner of this vehicle to ensure that the services technicians are properly trained, understand and obey the safety rules and guidelines (ANSI B56). All service technicians must read and understand the maintenance warning section in this manual.
  • Page 20 Maintenance REVERSE ONLY On a SEPEX motor control, check the forward signal input on the controller. On a series wound motor control, a bad forward contactor is the most probable cause of the problem. Switch to forward and check the voltage on the forward control wire. If not B+, replace the F/R switch. If B+, turn off the key switch, disconnect batteries, disconnect power terminals on the F/R contactors, check the resistance across N.C.
  • Page 21 Maintenance NO MOTION Make sure that the PMC surface is clean and dry; check the terminal areas. Dust Particles or acid contamination, can create current leaks and cause a PMC malfunction. Check F/R switch Turn on the key switch and set to forward. Check voltage between the forward terminal and the –...

  • Page 22: Curtis Speed Controller

    Curtis Speed Controller CURTIS SPEED CONTROLLER - 22 -...
  • Page 23 MANUAL 12 4 4 MultiMode™ MOTOR CONTROLLER © 2001 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. CURTIS PMC 235 East Airway Boulevard 1244 Manual, p/n 16958 Livermore, California 94568 USA Rev. B: January 2001 Tel: 925-961-1088 Fax: 925-961-1099 www.curtisinst.com...
  • Page 24 1244 Manual p/n 16958, Rev. B: January 2001 © 2001 CURTIS INSTRUMENTS, INC. CURTIS INSTRUMENTS, INC. 200 KISCO AVENUE MOUNT KISCO, NEW YORK 10549 USA 914-666-2971 914-666-2188 CURTIS PMC 235 EAST AIRWAY BOULEVARD LIVERMORE, CALIFORNIA 94550 USA 925-961-1088 925-961-1099 ADDITIONAL OFFICES located in Bulgaria, China, England, France, Germany, India, Italy, Japan, Netherlands, Puerto Rico, Russia, Sweden, and Switzerland...

  • Page 25: Wiring: Standard Configuration

    2 — INSTALLATION & WIRING: Controller WIRING: Standard Configuration Figure 3 shows the typical wiring configuration for most applications. The interlock switch is typically a seat switch, tiller switch, or foot switch. Standard Power Wiring Motor armature winding is straightforward, with the armature’s A1 connection going to the controller’s B+ bus bar and the armature’s A2 connection going to the controller’s M- bus bar.

  • Page 26: Diagnostics And Troubleshooting

    8 — DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING The 1244 controller provides diagnostics information to assist technicians in troubleshooting drive system problems. The diagnostics information can be obtained by observing the appropriate display on the handheld programmer, the fault codes issued by the Status LED, or the fault display driven by the controller’s Fault 1 and Fault 2 outputs.

  • Page 27: Troubleshooting Chart

    8— DIAGNOSTICS & TROUBLESHOOTING TROUBLESHOOTING CHART Table 5 PROGRAMMER FAULT EXPLANATION POSSIBLE CAUSE CODE LCD DISPLAY CATEGORY self-test or watchdog fault 1. Controller defective. HW FA I L SA FE 1 - 2 - 3 internal M- short to B- 1.

  • Page 28: Led Diagnostics

    8 — DIAGNOSTICS & TROUBLESHOOTING LED DIAGNOSTICS A Status LED is built into the 1244 controller. It is visible through a window in the label on top of the controller. This Status LED displays fault codes when there is a problem with the controller or with the inputs to the controller. During normal operation, with no faults present, the Status LED flashes steadily on and off.

  • Page 29: Programming Parameters - E-290Hd, E-348, E-480, E-500, E-660, T-248, T-448

    Curtis Speed Controller PROGRAMMING PARAMETERS – E-290HD, E-348, E-480, E-500, E-660, T-248, T-448 ! WARNING ! The owner of this vehicle shall ensure that the service technicians are qualified, properly trained and obey the safety rules and guidelines in OSHA and ANSI B56 regulations, and in this manual.

  • Page 30: Curtis Pmc Motor Controller

    Curtis Speed Controller CURTIS PMC MOTOR CONTROLLER - 30 -...
  • Page 31 MANUAL 1204X/1205X 1209/1221 MOTOR CONTROLLERS © 1999 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. CURTIS PMC 235 East Airway Boulevard 1204X / 1205X / 1209 / 1221 Manual Livermore, California 94568 USA p/n 98796, Rev.

  • Page 32: Overview

    OVERVIEW OVERVIEW Curtis PMC Model 1204X/1205X and 1209/1221 electronic motor speed controllers are designed to provide smooth, silent, cost-effective control of motor speed and torque on a wide variety of industrial electric vehicles. Curtis PMC Fig. 1 1205X full-feature electronic motor controller.
  • Page 33 OVERVIEW ✓ Fault detection circuitry monitors battery, throttle connections, output transistors, bypass contactor, etc., to prevent runaway conditions ✓ Static return to off (SRO) function requires that forward or reverse selectors be returned to neutral before output is allowed [optional feature] ✓...

  • Page 34: Wiring : Standard Configuration

    WIRING WIRING CONNECTIONS: Low Current Two 1/4" push-on terminals are provided for the throttle inputs. If your controller has a voltage throttle input, there will be only one throttle terminal. A 6-pin low power connector molded into the right side of the controller face provides the low power logic control connections—KSI input, forward/ reverse contactor output, bypass contactor output (optional), emergency reverse (optional), and forward and reverse inputs.
  • Page 35 WIRING CONNECTIONS: High Current Four tin-plated solid copper bus bars are provided for the high current connec- tions to the battery and motor. Negative connection to battery Positive connection to battery and to motor armature Output to motor field Plug diode to motor armature The cables used for the battery and motor connections must be heavy enough to carry the high current required.
  • Page 36 WIRING (*not used with SRO controllers) CONTROL WIRING PEDAL KEYSWITCH INTERLOCKS FUSE MICROSWITCH POLARITY PROTECTION DIODE POWER WIRING MAIN FUSE PRECHARGE RESISTOR (250 Ω, 5 W) POTBOX – F/R cont. output Bypass cont. output Emergency reverse ** FWD input REV input 1A BYPASS (**See Figure 10 for emergency reverse.)

  • Page 37: Maintenance And Adjustment

    MAINTENANCE & ADJUSTMENT MAINTENANCE & ADJUSTMENT Curtis PMC 1204X/1205X/1209/1221 controllers and potboxes require only minimal maintenance if properly installed. : The controllers are sealed and NOTE thus are not field serviceable. CONTROLLER Maintenance It is recommended that the following two steps be performed occasionally. First ☞...
  • Page 38 MAINTENANCE & ADJUSTMENT Adjustment pots. Fig. 16 CURRENT LIMIT ADJUST (CCW = lower current limit) PLUG CURRENT ADJUST ACCELERATION RATE ADJUST (CW = higher plug current) (CW = faster acceleration) Use the following adjustment procedure. The keyswitch should be off during adjustment.
  • Page 39 MAINTENANCE & ADJUSTMENT 2. If adjustment is required, loosen the screw holding the lever on the pot shaft. Use a screwdriver to rotate the pot shaft slightly with respect to the lever. Recheck the point at which the resistance starts to increase and continue making adjustments until the increase starts at 3 mm (1/8") [at 1.5 mm (1/16") for potboxes without the microswitch].

  • Page 40: Spare Parts

    Spare Parts SPARE PARTS - 40 -...

  • Page 41: Body

    Spare Parts BODY PART NO DESCRIPTION 2383320004 SEAT 1005003 BUCKET SEAT ON SLIDE ADJUSTERS 120003 TRIMMING 2315320001 FRONT COWL SAFETY BUMPER 2223360001 SOLID SOFT RUBBER WHEEL, LUG THREAD 300026RIB SOLID SOFT RUBBER WHEEL, RIB THREAD 300026W NON MARKING WHEEL, LUG THREAD 300026WRIB NON MARKING WHEEL, RIB THREAD 2382320011...

  • Page 42: Cab

    Spare Parts REF PART NO DESCRIPTION PART NO DESCRIPTION 2360320012 STEEL CAB 2801000002 REAR VIEW MIRROR 2382320009 SEATBACK CAB 2802000001 TRIM DOOR 2360320014 RIGHT DOOR 2801000001 SIDE MIRROR 2360320015 LEFT DOOR 2399000014 SIDE MIRROR BRACKET 2360320024* RIGHT DOOR, REAR PASSENGERS 10 3113000001 WIPER MOTOR 2360320025*...

  • Page 43: Ford F-150 Differential

    Spare Parts FORD F-150 DIFFERENTIAL - 43 -...
  • Page 44 Spare Parts - 44 -...

  • Page 45: Brake Controls

    Spare Parts BRAKE CONTROLS REF PART NO DESCRIPTION REF PART NO DESCRIPTION Nut 1/4-20UNC 2190000003 Spring ( Extention ) 2910000015 Yoke 2910000013 Yoke Lock washer ¼ Cotter pin 3/32 x 1 2930000012 Lubrication fitting Flat washer 5/16 2131100002 Rubber pad Clevis pin 5/16 x 1-1/2 2131360002 Lever...

  • Page 46: Front Assembly

    Spare Parts FRONT ASSEMBLY - 46 -...
  • Page 47 Spare Parts PART NO DESCRIPTION PART NO DESCRIPTION 2100300002 BUSHING 2219250001 SPACER 2100300001 BUSHING WITH OIL SEAL 2224300002 2100300003 BUSHING 2229300001 DUST CAP 2103250001 THRUST BEARING 2229300002 OIL SEAL 2103300001 TAPER BEARING 2229300003 SPINDLE WASHER 2103300002 TAPER BEARING 2910000005 NUT, LEFT HAND 2104300004 OIL SEAL 2910000006...

  • Page 48: Motor And Drive

    Spare Parts MOTOR AND DRIVE COMMON PARTS DESCRIPTION PART # DESCRIPTION PART # 1 PULLEY 262424 8 MOTOR BASE, FORD Contact manuf. 2 V BELT 242431 BELT TENSIONER 2152002 3 PULLEY 3651001 9 SEAL 484001 4 BELT, EAGLE 3651002 10 BEARING 484003 5 MOTOR BASE, GM Contact manuf.

  • Page 49: Rear Suspension And Brake

    Spare Parts REAR SUSPENSION AND BRAKE - 49 -...
  • Page 50 MACHINE SCREW 1/4-NC X 3/8 NYLON NUT 5/8-NC HEAVY NUT 1/2-NF 2183240002 BUSHING * E-302 & 348 ** E-320, 322, 330, 360 & 480 *** STANDARD, E-500 & 660 AND OPTIONAL, E-320, 322, 330, 360 & 480 - 50 -...

  • Page 51: Electrical Diagram - Sepex Main Circuit

    Spare Parts ELECTRICAL DIAGRAM – SEPEX MAIN CIRCUIT DIAGRAMME ÉLECTRIQUE – CIRCUIT PRINCIPAL SEPEX - 51 -...

  • Page 52: Electrical Diagram - Series Main Circuit

    Spare Parts ELECTRICAL DIAGRAM – SERIES MAIN CIRCUIT DIAGRAMME ÉLECTRIQUE – CIRCUIT PRINCIPAL SÉRIES - 52 -...

  • Page 53: Accessories - No Dc/Dc Converter

    Spare Parts ACCESSORIES – NO DC/DC CONVERTER ACCESSOIRES – SANS CONVERTISSEUR DC/DC - 53 -...

  • Page 54: Accessories - Dc-Dc Converter

    Spare Parts ACCESSORIES – DC-DC CONVERTER ACCESSOIRES – CONVERTISSEUR DC-DC - 54 -...

  • Page 55: Options

    Spare Parts OPTIONS - 55 -...
  • Page 56 PVC GROUNDING PLUG, YELLOW 80003 36 VOLT MAIN CONTACTOR 3104236001 48 VOLT MAIN CONTACTOR 486222 Y2.A,B 36 VOLT F/R CONTACTOR 366217 48 VOLT F/R CONTACTOR 486217 HEATER SOLENOID 246101 F/R BUSSBARS 2469003 STATIC STRAP 2450001 * Consult Motrec Illustrated parts - 56 -...

  • Page 57: Battery Configurations - 48V

    Spare Parts BATTERY CONFIGURATIONS - 48V CONFIGURATIONS DES BATTERIES – 48V - 57 -...

  • Page 58: Built-In / Portable 25A Charger

    Spare Parts BUILT-IN / PORTABLE 25A CHARGER Parts list for LESTRONIC II charger MODEL 09695 TYPE 48LC25-8ET 115 VAC 60 Hz PART NO DESCRIPTION 09727S CASE ASSEMBLY 09696S TRANSFORMER ASSEMBLY 16354S HEATSINK ASSEMBLY, WITH DIODES 04127S AMMETER ELECTRONIC TIMER ASSEMBLY (RELAY – 03735S) 09664S 02390S CAPACITOR, 6.0 MFD, 660 VAC...

  • Page 59: Built-In/Portable Charger Model 16510

    Spare Parts BUILT-IN/PORTABLE CHARGER MODEL 16510 Parts list for MODEL 16510 TYPE 48EL20-8ET 100-125 or 200-250 VAC / 50-60 Hz PART NO QTY. DESCRIPTION 21149S CASE ASSEMBLY 15945S TRANSFORMER ASSEMBLY 16369S AMMETER 16595S ELECTRONIC TIMER ASSEMBLY 18696S SHUNT ASSEMBLY 21249S HEATSINK ASSEMBLY, W/ SCR 21152S CONTROL CABLE ASSEMBLY...

  • Page 60: Delta-Q Hf Charger

    Spare Parts DELTA-Q HF CHARGER PART NO DESCRIPTION 24V CHARGER ( U.S. BATTERY ) 3102240002 3102240003 24V CHARGER ( LIFELINE BATTERY ) 3102240004 24V CHARGER ( GEL 180AH BATTERY) 3102240005 24V CHARGER ( 27TM BATTERY ) 36V CHARGER ( U.S. BATTERY ) 3102302001 3102302002 36V CHARGER ( LIFELINE BATTERY )
  • Page 61 Spare Parts - 61 -...
  • Page 62 Spare Parts - 62 -...

  • Page 63: Motrec Illustrated Accessories

    Spare Parts MOTREC ILLUSTRATED ACCESSORIES Headlight Red Tail/Brake light Left: 3111480003 Strobelight, polemount Housing: 3069012R Horn button VIP Right: 3111480004 Amber 12-80V: 3116000001 Bulb 12V: 3117240001 2330014 Bulb H/L: 3117480001 Red 12-80V: 2469001 Bulb Turn: 3117480003 Blue 12-80V: 3690008 Bulb Mark:...
  • Page 64 Spare Parts Pantograph wiper blade Wiper motor 246233 12V: 3113000001 24V: 486211 Analog Voltmeter Headlamp 12V: 3111250002 12V : 3069007 24V : 2469002 36-48V : 3669002 Cab heater 12V: 3103300001 Wiper arm 2800000001 36V: 3669008 Headlamp 48V: 4869020 12V: 3111300001 Bulb 12V: 3111300002 HOBBS Gauge...

  • Page 65: Battery Discharge Indicator (Hobbs)

    Spare Parts BATTERY DISCHARGE INDICATOR (HOBBS) This indicator monitors : the residual capacity of batteries; operating hours; status of service down counter. The residual capacity of the battery is monitored via an 8-LED bar display. When the left red LED lights, the batteries must be charged to avoid damage.

  • Page 66: Addendum

    Addendum ADDENDUM - 66 -...

  • Page 67: Curtis Foot Pedal

    Addendum CURTIS FOOT PEDAL REF. PART. NO DESCRIPTION 3062001C ACCELERATOR CURTIS 367008 POTENTIOMETER 2262004C SPRING 2262001C MICRO-SWITCH 2262003C LEVER 3662002 CABLE PROTECTOR E-320/360/480/500 CLAUDE L RESP : MODEL(E) : 321A320001 1018799 1019973 NO : SER : TO/À : - 67 -...

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