Motrec T-448HD Installation instructions

T-448HD
OPERATOR AND MAINTENANCE MANUAL
SPARE PARTS LISTS INCLUDED
SERIAL NUMBER : 1006000 & UP
Printed in Canada

19/12/2005
One Year Limited Warranty
Effective April 25, 2005, MOTREC, Inc. (MOTREC) hereby warrants to the Original Retail Purchaser (Owner) that any of its
vehicles shall be free from any defect in materials for a period of 90 DAYS while in the possession of such Original Retail
Purchaser. This warranty IS NOT TRANSFERABLE to any subsequent Buyer.
The warranty period is extended to one year or one thousand (1,000) hours, which ever first occurs, on the electric motor,
differential (parts that bathe in oil) and the electronic speed controller. MOTREC makes no warranty or representation with
respect to the internal combustion engine, tires and batteries, since their respective manufacturers cover such parts.
Accessories (light, gage, horn, etc), electrical contacts (switch, solenoid, contactor, relay), diodes & fuses, belts & pulleys,
filters & spark plugs, lubricants, brake linings & shoes, brake drums & discs, seals, seats, trim and other items subject to
wear are not included in this warranty; nor is any item that in MOTREC sole opinion, shows evidence of neglect, misuse,
abuse, collision or alteration.
This warranty shall not apply to normal maintenance requirements as described in the User Manual, and to damages during
shipment. The latter is the carrier's responsibility. No compensation will be allowed for delays.
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.
The defective vehicle must be returned, at the Owner's expense, to an authorised MOTREC Dealer within 30 days after
failure. The Owner will not be charged for parts and labour required for warranty repairs, which must be performed by an
authorised MOTREC Dealer only. 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 will be
allowed for damages caused by vehicle downtime.
It is the responsibility of the owner of the vehicle to make sure that the driver is properly trained and instructed in the safety
features and operation of the vehicle, including vehicle stability, as required by OSHA and ANSI-B56. Operators shall read,
understand and follow the safety and operating instructions in MOTREC Manual before driving the vehicle. Operators shall
not be permitted to drive the vehicle unless a complete and adequate training has been provided. Driving a vehicle
constitutes a hazard. The driver is responsible for the control of the vehicle while driving and must always evaluate and care
for all peculiar situations that he or she may meet while driving. The driver assumes the inherent hazards related to this
activity. The vehicle is designed for off-road use only. MOTREC disclaims any liability for incidental or consequential
damages, to include, but not be limited to, personal injury or property damage arising from vehicle misuse, lack of
maintenance or any defect in the vehicle.
It is the responsibility of the Owner of the vehicle to make sure that the service technicians are properly trained as required
by OSHA and ANSI-B56. Service technicians shall read, understand and follow instructions in the MOTREC manual before
servicing the vehicle. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect the
vehicle.
MOTREC prohibits, and disclaims responsibility for, any vehicle modification altering the weight distribution and stability,
increasing the speed or affecting the safety of the vehicle. Such modifications can cause serious personal injury or property
damage for which MOTREC disclaims any responsibility.
For Owners that are located outside North America, the warranty period starts the date of shipment from the factory, and the
defective parts must be returned at the Owner's expense to MOTREC prior to warranty repair.

Table of contents
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TABLE OF CONTENTS
INSTRUCTIONS 4
SAFETY WARNINGS FOR OPERATORS 5
OPERATING INSTRUCTIONS 6
MAINTENANCE 7
SAFETY WARNINGS FOR SERVICE TECHNICIANS 8
DECALS AND LABELS 10
PERIODIC MAINTENANCE CHECKLIST 11
ACCELERATOR 12
BELT INSTALLATION AND TENSIONING 13
HYDRAULIC BRAKES 14
FRONT AXLE AND STEERING 15
BATTERY MAINTENANCE 16
BATTERY CHARGER 18
ELECTRICAL TROUBLESHOOTING 19
SERIES SPEED CONTROLLER 22
ELECTRICAL DIAGRAM 24
CURTIS SPEED CONTROLLER 26
WIRING :STANDARD CONFIGURATION 29
DIAGNOSTICS AND TROUBLESHOOTING 30
TROUBLESHOOTING CHART 31
LED DIAGNOSTICS 32
PROGRAMMING PARAMETERS –E-480TT, T-448HD 33
SPARE PARTS 34
BODY 35
FORD F-150 DIFFERENTIAL 36
BRAKE CONTROLS 38
FRONT AXLE, SUSPENSION, STEERING, DISC BRAKES 39
D00-4002 SEPEX MOTOR AND DRIVE 41
REAR SUSPENSION 42
ELECTRICAL DIAGRAM –SEPEX MAIN CIRCUIT 43
ACCESSORIES –DC-DC CONVERTER 44
OPTIONS 45
MOTREC ILLUSTRATED ACCESSORIES 47
CONVERTER INSTALLATION 49
BATTERY DISCHARGE INDICATOR (HOBBS) 50
CURTIS FOOT PEDAL 51

Instructions
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INSTRUCTIONS

Instructions
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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. Owner shall comply with OSHA and ASME/ANSI B56.8 & B56.9 regulations for vehicle use,
safety rules, operator training and certification. Do not drive this vehicle unless you are a qualified operator.
•Do not drive this vehicle under the influence of drugs or alcohol.
•Do not drive this vehicle on public roads and highways. This vehicle is designed to be driven in buildings.
•The electrical system of this vehicle will make sparks which can ignite inflammable materials. Never use the
vehicle in hazardous areas where there are inflammable materials, explosive dust or fumes in the air.
•Have your vehicle inspected regularly by trained personnel, and cease operation if a malfunction occurs.
•Do not open battery compartment to prevent battery explosion, acid splashing, severe damage to eyes or skin.
•Do not open motor compartment. Keep clear from moving, rotating(wheels, sheaves, etc) or lifting parts.
•Never carry more passengers than number allowed for this vehicle. Wait until all occupants are seated and
holding on before moving. Always keep all body parts inside vehicle. Keep both hands on steering wheel.
•Do not exceed the vehicle cargo load capacity and gross trailing weight capacity, rated for flat hard even surface.
Different operating 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 vehicle. Do not carry cargo that is longer, wider or higher than this vehicle.
•Always depress slowly the accelerator for smooth acceleration. Avoid stunt driving or horseplay.
•Avoid sharp turns, always slow down before turning, to prevent vehicle overturn or trailer jack knife. Vehicle is
more sensitive to overturn and jack knife when traveling on inclines or when carrying a heavy load.
•Always drive straight up and down the face of an incline, never across the face, to prevent overturn and trailer
jack knife. Drive slower and start applying brakes sooner on inclines to adjust for longer stopping distance.
•Use extra care and drive slowly in reverse, in congested areas or on wet or slippery ground.
•Keep to the right under normal conditions. Maintain a safe distance from all objects.
•Slow down and sound the horn when approaching a corner or other blind intersections.
•Before leaving the vehicle, park on a level ground flat surface, turn off all switches, set the forward/reverse
switch to neutral, set the parking brake, remove the key. Do not park the vehicle on an incline.
•Before battery charging, park the vehicle in a well ventilated area set for. Do not operate it when charging. To
interrupt a charging cycle, disconnect the AC plug; disconnecting the DC plug or a battery terminal, or operating
the vehicle, could damage the charger and produce a spark, battery explosion and acid splashing.
•Use another driver to steer this vehicle while it is towed. Be sure the driver uses brakes when you slow or stop
the towing vehicle. Do not exceed 5 MPH or carry any passenger while towing this vehicle.