Related Manuals for Motrec T-448N
Summary of Contents for Motrec T-448N
- Page 1 T-448N OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER: 1035052 & 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.
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Page 3: Table Of Contents
49 ELECTRICAL DIAGRAM – SEPEX MAIN CIRCUIT 50 ELECTRICAL DIAGRAM – SERIES MAIN CIRCUIT 51 ACCESSORIES – DC-DC CONVERTER 52 OPTIONS 53 MOTREC ILLUSTRATED ACCESSORIES 55 CONVERTER INSTALLATION 57 BATTERY DISCHARGE INDICATOR (HOBBS) 58 ADDENDUM 59 CURTIS FOOT PEDAL 60 ... -
Page 4: Instructions
Instructions INSTRUCTIONS - 4 -... -
Page 5: Safety Warnings For Operators
Instructions SAFETY WARNINGS FOR OPERATORS • FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN 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 (ANSI B56). Do not drive this vehicle unless you are a certified operator as required by OSHA. BEFORE USING VEHICLE Before turning on key switch: set to neutral, check for any visible damage, check brake pedal. -
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 ASME/ANSI B56.8 & B56.9 regulations for vehicle maintenance. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect carriers, vehicles, tractors, and batteries. - 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.
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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: Respectively, key switch markings, forward/reverse selector markings and light switch marking:... -
Page 11: Periodic Maintenance Checklist
Maintenance PERIODIC MAINTENANCE CHECKLIST ! 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 −... -
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. −... -
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 Brakes
Maintenance HYDRAULIC BRAKES DRUM BRAKES Remove brake drums and check linings wear; the linings should have a thickness exceeding 1/16" (1.5 mm). Turn the brake adjustment to reduce the clearance between lining and drum but avoid contact or drag when the wheels are turned and the pedal is released. DISC BRAKES Check pad linings for excessive wear;... -
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 −... -
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. −... - 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 −...
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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; −... -
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 –...
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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...
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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. Before installing and/or programming the PMC, park the vehicle on a flat level surface, lift the wheels off the ground and secure with jack stands of adequate capacity. -
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.
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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] ✓...
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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.)
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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].
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Page 40: Spare Parts
Spare Parts SPARE PARTS - 40 -... -
Page 41: Body
Spare Parts BODY REF. PART NO DESCRIPTION 1005003 BUCKET SEAT ON SLIDE ADJUSTER 4402003 SEAT BACK CUSHION (NOT ILLUSTRATED) SEAT CUSHION (NOT ILLUSTRATED) 2383320004 2331448001 BATTERY COVER 2330448001 MOTOR COVER 2339448004 CONTROLS COVER 300022 5.7X8 LRD WHEEL 300024H 5.7X8 NSH, TITAN PREMIUM, WHEEL 2223360001 5.00 X 8 SOLID, SOFT RUBBER, WHEEL 2314320005... -
Page 42: Cab
Spare Parts PART NO DESCRIPTION PART NO DESCRIPTION 2360448001 STEEL CAB 2801000001 SIDE MIRROR 2360320014 RIGHT DOOR 2399000014 SIDE MIRROR BRACKET 2360320015 LEFT DOOR 3113000001 WIPER MOTOR 2803000003 PADDLE LATCH 2800000002 WIPER 2366320015 DOOR LATCH 2800000001 2365000001 RIGHT HINGES KIT 2366320001 DOOR HANDLE 2365000002... -
Page 43: Ford F-150 Differential
Spare Parts FORD F-150 DIFFERENTIAL - 43 -... - Page 44 Spare Parts - 44 -...
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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 Axle, Suspension, Steering, Disc Brakes
Spare Parts FRONT AXLE, SUSPENSION, STEERING, DISC BRAKES - 46 -... - Page 47 Spare Parts PART NO DESCRIPTION PART NO DESCRIPTION 2100300002 BUSHING 2224300002 2100300001 BUSHING WITH OIL SEAL 2229300001 DUST CAP 2100300003 BUSHING 2229300002 OIL SEAL 2103250001 THRUST BEARING 2229300003 SPINDLE WASHER 2103300001 TAPER BEARING 2910000005 NUT, LEFT HAND 2103300002 TAPER BEARING 2910000006 NUT, RIGHT HAND 2104300004...
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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 PART NO DESCRIPTION PART NO DESCRIPTION 2120236001 DISC 2182320002 SHACKLE LINK 481431K RIGHT CALIPER 2182448001 REAR SUSPENSION PLATE 481430K LEFT CALIPER 2185280001 FORD PLATE 2121000005 BUSHING, LONG 2192320001 5 - LEAF SPRINGS 2121000006 BUSHING, SHORT 2910000017 BOLT, LONG 2122236001... -
Page 50: Electrical Diagram - Sepex Main Circuit
Spare Parts ELECTRICAL DIAGRAM – SEPEX MAIN CIRCUIT DIAGRAMME ÉLECTRIQUE – CIRCUIT PRINCIPAL SEPEX - 50 -... -
Page 51: Electrical Diagram - Series Main Circuit
Spare Parts ELECTRICAL DIAGRAM – SERIES MAIN CIRCUIT DIAGRAMME ÉLECTRIQUE – CIRCUIT PRINCIPAL SERIES - 51 -... -
Page 52: Accessories - Dc-Dc Converter
Spare Parts ACCESSORIES – DC-DC CONVERTER ACCESSOIRES – CONVERTISSEUR DC-DC - 52 -... -
Page 53: Options
Spare Parts OPTIONS - 53 -... - Page 54 EMERGENCY PUSH BUTTON 3109800001 EMERGENCY PUSH BUTTON LABEL 3109800006 DC-DC CONVERTER HOUR METER CONNECTOR SPEED CONTROL CONNECTOR SPEED CONTROL CONNECTOR MAIN CONTACTOR 486222 Y2.A,B F/R CONTACTOR 486217 F/R BUSSBAR 2469003 STATIC STRAP 2450001 * Consult Motrec Illustrated parts - 54 -...
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Page 55: 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 56 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...
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Page 57: Converter Installation
Spare Parts CONVERTER INSTALLATION - 57 -... -
Page 58: 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 59: Addendum
Addendum ADDENDUM - 59 -... -
Page 60: 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 : - 60 -...