Curtis 1204 User Manual

27
Curtis PMC 1204/1205 Manual
Fig. 19 Guide to troubleshooting procedures. [To use this guide, refer to the specified PROCEDURES .]
TROUBLESHOOTING & BENCH TESTING
D
if NO
if NO
if NO
1-D
1-D
1-C
2-D
2-D
2-E
3-A
3-C
3-E
3-B
3-C
3-E, F
4-C
4-D, E
4-F, G, H, I
Check voltage at CONTROLLER B- and BATTERY B+ terminals.
It should read full voltage for system.
1-A, B, C
if YES
Check voltage at CONTROLLER B- and CONTROLLER B+ terminals.
It should read 1 to 5 volts less than full battery voltage.
if NO
if NO
Check voltage at contactor and at KSI terminal.
Contactor should read full rated voltage, and KSI must be above 8V.
2-A, B, C
TEST
2 Check for main contactor operation and KSI
TEST
1 Check for power to the controller
TEST
3 Check potbox circuitry (0–5kΩ throttles)
Check voltage across contactor power terminals.
There should be no measurable voltage drop.
if YES
if YES
Check resistance at potbox wires while depressing pedal.
Resistance should be between 0–50 ohms with pedal UP, and
4500–5500 ohms with pedal
DOWN.
Check for shorts between potbox wires and vehicle frame.
Resistance should be at least 1 megohm.
Check voltage at upper throttle input terminal on controller.
Voltage should be 3.6 to 4.2 volts with pedal UP,
and 9.1 to 10.3 volts with pedal
DOWN.
if YES
if YES
TEST
4 Check for controller output
if YES
4-A, B, C
if NO
if NO
if NO
Check voltage output while depressing pedal (B+ to M-).
Voltage should be zero with pedal UP, and full battery voltage
with pedal
DOWN.
Check current in controller’s M- (motor field) lead while
depressing pedal.
Current should be high, and motor should turn.
Bad, discharged, or miswired
batteries, or corroded
connections.
TOO HIGH: contactor is welded.
TOO LOW: 250 Ω resistor or
controller is defective.
Trace flow to locate
problem.
If voltage drop occurs,
contactor is defective.
Defective potbox, broken wires
to potbox, or improper
mechanical operation.
If lower than 1 MΩ, wiring or
potbox is defective.
Controller is defective.
If no current, look for open
circuit. If current is high but
motor won’t turn, check motor,
wiring & plug diode.
Terminal area is probably
contaminated with acid or
dirt.

Curtis 1204 Specifications

General

Brand	Curtis
Model	1204
Category	Controller
Language	English