Motrec E-242HD, Operator And Maintenance Manual

Page 1: ...E 242HD OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1035396 UP Printed in Canada...

Page 2: ...ly The vehicle will be returned at the owner s expense The Warranty Claim Forms must be completed and returned with the defective part s to MOTREC within 30 days after repair was done No compensation...

Page 3: ...ART 25 LED DIAGNOSTICS 27 PROGRAMMING PARAMETERS E 242 E 242HD E 250 28 CURTIS PMC MOTOR CONTROLLER 29 WIRING STANDARD CONFIGURATION 31 MAINTENANCE AND ADJUSTMENT 33 SPARE PARTS 35 BODY 36 DIFFERENTIA...

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

Page 5: ...ing conditions such as loose terrain or ramps reduce vehicle capacity Avoid loose unbalanced or top heavy loads to keep a good stability and prevent overturn Do not load cargo that can fall off the ve...

Page 6: ...t as batteries are being discharged When the green light is at the last position on the left the batteries must be recharged A flashing light warns the operator that further discharge will damage batt...

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

Page 8: ...ools to avoid sparks that can cause battery explosion and acid splashing Use two counteracting tools double wrench technique when disconnecting or tightening terminals on the battery and the speed con...

Page 9: ...ower circuit to filter inductive loads in the event of a sudden power interrupt Some speed controllers require a diode to filter inductive loads on the KSI input Removing the diodes will cause the spe...

Page 10: ...n 3109800006 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 unalter...

Page 11: ...tes Fill to recommended level after batteries have been fully charged X WARNING DECALS MARKINGS X EE Rated CABLE PROTECTORS SEALED MOTOR SEALED CONTROL BOX STATIC STRAP X MASTER CYLINDER FLUID DOT 3 X...

Page 12: ...the on off solenoid when the accelerator is released turn the adjusting screw shown on figure below to adjust the micro switch height POT Remove the terminals 2 and 3 on PMC to measure resistance sig...

Page 13: ...til it contacts the smaller pulley Properly adjusted pulleys will provide three points of contact Properly aligned pulleys will provide four points of contact Tighten setscrews and recheck alignment T...

Page 14: ...s on the inboard side of the backing plates The levers must be equally pulled Adjust pulling rods if necessary The shoes are adjusted by turning the stud 17mm key located on the inboard side of the ba...

Page 15: ...in the controller with a 10 ohms 25 W resistor for a few seconds across B and B identify battery polarity and disconnect battery leads After cleaning the power must not be reapplied until terminal are...

Page 16: ...charger connected for more than 20 hours FREQUENCY OF CHARGE When a battery is discharged to its 20 state of charge it is best to charge immediately Batteries require a low current equalization charge...

Page 17: ...in the dc circuit Check diodes Check capacitor rapidely increasing resistance SINGLE CHARGER FUSE BLOWS Disconnect and check diodes BOTH FUSE LINKS BLOW Check the battery pack and battery connector po...

Page 18: ...voltage between and terminals We will call this value B or full battery voltage ACCESSORIES NOT WORKING Check the fuses on the batteries and the DC DC converter Check voltage across and terminals on t...

Page 19: ...sistance between terminals Other causes of lower speed dragging brakes cold temperature higher differential oil viscosity INTERMITTENT OPERATION A bad potentiometer is the most probable cause of the f...

Page 20: ...eck voltage across power terminals if not B check circuit breaker or replace the solenoid Turn to on the key switch and activate the seat switch Check voltage across the coil terminals if not B check...

Page 21: ...Curtis Speed Controller 21 CURTIS SPEED CONTROLLER...

Page 22: ...ONTROLLERS PROTECTED BY U S PATENT NO 4626750 CURTIS INSTRUMENTS INC 200 Kisco Avenue Mount Kisco NY 10509 USA Tel 914 666 2971 Fax 914 666 2188 www curtisinst com 1243GEN2 Manual p n 37044 Rev A Octo...

Page 23: ...cations For walkie applications the interlock switch is typically activated by the tiller and an emergency reverse switch on the tiller handle provides the emergency reverse signal For rider applicati...

Page 24: ...ave occurred since the fault history le was last cleared Checking and clearing the fault history le is recommended each time the vehicle is brought in for maintenance For information on 1311 programme...

Page 25: ...2 EMR REV WIRING 1 1 Emergency reverse wire or check wire Re apply emergency reverse open or cycle interlock 2 3 HPD 3 1 Improper sequence of KSI interlock Follow proper sequence and throttle inputs...

Page 26: ...nently MOTOR HOT 3 1 Field resistance motor hot setpoint When resistance setpoint MOTOR WARM 3 1 Field resistance motor warm setpoint When resistance setpoint Fig 21 Curtis 840 Spyglass 3 LED and 6 LE...

Page 27: ...er or defective controller solid on controller or microprocessor fault 0 1 controller operational no faults 1 1 current sensor error 1 2 hardware failsafe fault 1 3 M fault or motor output short 1 4 s...

Page 28: ...N SEC 2 BDI LOCKOUT BDI LOCKOUT ON OR OFF OFF M2 BRAKE RATE MODE 2 BRAKING RATE IN SEC 2 BDI DISABLE BDI DISABLE ON OF OFF OFF M3 BRAKE RATE MODE 3 BRAKING RATE IN SEC 2 ADJ HRS LOW ADJ HRS LOW 0 TO 9...

Page 29: ...Curtis Speed Controller 29 CURTIS PMC MOTOR CONTROLLER...

Page 30: ...00 SERIES CONTROLLERS PROTECTED BY U S PATENT NO 4626750 MODEL 1204 5 MOTOR CONTROLLERS CURTIS PMC 235 East Airway Boulevard Livermore California 94568 USA Tel 925 961 1088 F ax 925 961 1099 www curti...

Page 31: ...rmature A2 plug diode to motor armature W IRIN G 3 KSI throttle inputs 3 2 1 A2 M B B the high current required A minimum size of 25 mm2 4 AWG is recommended Rubber insulated welding cable is convenie...

Page 32: ...KSI circuit includes input from the keyswitch and from the various interlocks The controller KSI is used to turn the controller on and off KSI is turned on by connecting it to battery B Any positive...

Page 33: ...ess use two opposing wrenches This double wrench technique will help avoid putting stress on the bus bars which could crack the seals Always use insulated wrenches 2 Inspect all seals at the front and...

Page 34: ...t pots Use the following adjustment procedure The keyswitch should be off during adjustment 1 Remove the socket head screw 1 8 Allen for the adjustment you want to make 2 Adjust the internal potentiom...

Page 35: ...Spare Parts 35 SPARE PARTS...

Page 36: ...AR FOOTSTEP 2401004 12 REAR FOOTSTEP WITH CLEVIS 2401005 12 REAR FOOTSTEP CLEVIS SPRING 10 240105 BAR 11 240106 FRONT BUMPER 12 243001 4 80 X 8 PNEUMATIC WHEEL 4 BOLT 283001 4 80 X 8 PNEUMATIC WHEEL 5...

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

Page 38: ...62081 PULLEY 12 O D 16 242060 OIL SEAL 17 242061 TAPER BEARING 18 Contact manuf HOUSING 20 242063 BREATHER 21 242064 SPACER 22 242065 TAPER BEARING 23 242066 SHIM 24 Contact manuf GEAR KIT 26 242068 S...

Page 39: ...O DESCRIPTION REF PART NO DESCRIPTION 1 242051 DRUM 8 2123242001 DRUM 4 BOLT 2 BOLT 5 16 NC X 3 4 2123240001 DRUM 5 BOLT 3 242841 BACK PLATE 9 2413002 BACKING PLATE LH 4 242842 BRAKE SHOE 2413010 BACK...

Page 40: ...6 SPING 7 242830 OLD BRAKE LEVER 2416006 NEW BRAKE LEVER 8 242831 PIVOT 9 BOLT 3 8 NC X 3 10 242816 SPRING 11 242817 LUBRICATION FITTING 12 PIN 3 8 X 1 13 2416017 PIVOT DRAWBAR 14 242836 BAR 15 241601...

Page 41: ...ARING 7 241427 FORK 2 44 BEARING O D 25 241004 HUB 4 BOLT 281427 FORK 3 31 BEARING O D 281004 HUB 5 BOLT 9 281409 SHOCK ABSORBER 26 241005 WHEEL BOLT 10 281410 SUSPENSION ARM 27 241006 BUSHING 12 LOCK...

Page 42: ...pare Parts 42 STEERING WHEEL REF PART NO DESCRIPTION 241430 STEERING WHEEL ASS 1 481453 COVER 2 481452 NUT 3 481451 STEERING WHEEL 4 481454 SPRING PIN 5 481437 BUSHING 6 2830011 SUPPORT 7 2830004 SHAF...

Page 43: ...ASHER PACK 484006 BELT TENSIONER SHORT 2452003 15 WAVY WASHER 484013 7 PIVOT 2452002 19 HEADBAND 484015 EE HEADBAND KIT A91 107A SPECIFIC REF DESCRIPTION A89 B98 A00 D00 SEPEX DC3 SEPEX DANA DRIVE MOT...

Page 44: ...XLE FRAME REF PART NO DESCRIPTION 1 242621 SHOCK ABSORBER 2 242622 COIL SPRING 3 SPRING RETAINER 242623 BEFORE SERIAL 1012672 UP 2440008 SERIAL 1012672 UP 4 242602 BUSHING 7 BOLT 5 8 NC X 4 8 LOCK NUT...

Page 45: ...Spare Parts 45 ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT DIAGRAMME LECTRIQUE CIRCUIT PRINCIPAL SEPEX...

Page 46: ...Spare Parts 46 ELECTRICAL DIAGRAM SERIES MAIN CIRCUIT DIAGRAMME LECTRIQUE CIRCUIT PRINCIPAL S RIES...

Page 47: ...Spare Parts 47 ACCESSORIES NO DC DC CONVERTER ACCESSOIRES SANS CONVERTISSEUR DC DC...

Page 48: ...0001 1 MICROSWITCH 367002 1 POTENTIOMETER 367003 1 PLASTIC GEAR 367015 1 SPRING 2462008 1 R2 RESISTANCE 250 OHMS 367014 1 S1 KEY SWITCH 246205 1 S3 SEAT SWITCH MICRO SWITCH 3109100002 1 SEAT SWITCH SE...

Page 49: ...Spare Parts 49 BATTERY CONFIGURATIONS 24V CONFIGURATIONS DES BATTERIES 24V...

Page 50: ...RELAY 04483S 04483S RELAY TIMER KIT 36 VDC 02028S BUSHING 7W 2 INSULATOR FOR CORDSETS 03574S CORDSET AC 07874S CORDSET AC 14 3 12 MOLDED PLUG 08512S CORDSET DC NO PLUG 12 2 108 14284S CORDSET DC NO PL...

Page 51: ...BLY 4483D RELAY 08774S FUSE ASSEMBLY 02390S CAPACITOR 6 0 MFD 660 VAC 02008S BUSHING 7W 2 INSULATOR FOR DC CORD 02028S BUSHING 7K 2 INSULATOR FOR AC CORD 02506S CORDSET AC 08511S CORDSET DC NO PLUG 18...

Page 52: ...PACITOR 6 0 MFD 660 VAC 08776S FUSE ASSEMBLY 02028S BUSHING 7W 2 INSULATOR FOR DC CORD 03894S BUSHING 7K 2 INSULATOR FOR AC CORD 11923S CORDSET AC 08020S CORDSET DC WITH LESTER PLUG 12227S CORDSET DC...

Page 53: ...BUSHING INSULATOR 7W 2 FOR DC CORDSET 03894S 1 BUSHING INSULATOR 7K 2 FOR AC CORDSET 20916S 1 CORDSET AC 16 3 80 MOLDED PLUG 33016S 1 CORDSET AC 14 3 248 MOLDED PLUG 20924S 1 CORDSET DC 12 2 108 SB 5...

Page 54: ...02240004 24V CHARGER GEL 180AH BATTERY 3102240005 24V CHARGER 27TM BATTERY 3102302001 36V CHARGER U S BATTERY 3102302002 36V CHARGER LIFELINE BATTERY 3102302003 36V CHARGER GEL 180AH BATTRY 3102480002...

Page 55: ...Spare Parts 55...

Page 56: ...Spare Parts 56...

Page 57: ...up lamp Grommet 3269001 12V 3669012 24V 3669012A Clear lamp 12V 3069012 Bulb 12V 1269008 Pedestral head lamp 12V 2569001 Bulb 12V 2569001B Bulb 24V 4469001 Headlight Left 3111480003 Right 3111480004 B...

Page 58: ...4V 486211 Wiper arm 2800000001 Wiper blade 14 Blade 2800000002 18 Blade 2800000003 Pantograph wiper arm 246233A Pantograph wiper blade 246233 Cab heater 12V 3103300001 36V 3669008 48V 4869020 12V Dome...

Page 59: ...good battery performance it is recommended to limit the discharging to 80 of the battery capacity The recommended setting for 6V batteries is F and the recommended setting for an industrial battery is...