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Motrec E-322, Operator And Maintenance Manual

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Motrec E-322 Operator And Maintenance Manual Download Page 48

Spare Parts 

 

- 47 - 

PARTS LIST

 

 

NO 

DESIGNATION 

REF 

QTY 

A1 

SEPEX SPEED CONTROL 

1243-4320 

1 

B1 

STROBE LIGHT 

* 

1 

B2 

HORN 

* 

1 

B3 

REVERSE ALARM 

* 

1 

E1.A,B 

HEADLIGHT 

* 

2 

E2.A,B 

TAIL/BRAKE LIGHT 

* 

2 

E3.A,B 

AMBER FRONT LIGHT 

* 

2 

F1.A,B,C  FUSE, 15A 

246108K 

3 

F3 

CIRCUIT BREAKER, 150A 

3107000002 

1 

F5 

DIODE BRIDGE 

3669027 

1 

F6 

FUSE, 30A 

4890028 

1 

G1 

BATTERY 

 

1 

G2 

BATTERY CHARGER 

 

1 

K1 

FLASHER RELAY (INCANDESCENT) 

3069004 

1 

 

FLASHER RELAY (LED) 

3127000002 

1 

K2 

110 VAC RELAY 

366213 

 

 

RELAY BASE 

246216 

 

 

RELAY RETAINING CLIP 

246216C 

 

M2 

SEPEX MOTOR 

 

1 

M4 

WIPER MOTOR 

* 

1 

M7 

CAB HEATER 

* 

 

P1 

INDICATOR (BDI), HOUR METER 

* 

1 

R1 

ACCELERATOR 

2142100001 

1 

 

PLASTIC GEAR 

367015 

1 

 

MICROSWITCH 

3109100001 

1 

 

POTENTIOMETER 

367003 

1 

 

SPRING 

2462008 

1 

S1 

KEY SWITCH 

246205 

1 

S3 

SEAT SWITCH 

3109000003 

1 

 

CONNECTOR 

3109000004 

 

S7 

FORWARD/REVERSE SELECTOR 

266211 

1 

S8 

LIGHT SWITCH, ROCKER TYPE 

1269004 

1 

 

LIGHT SWITCH, PUSH/PULL 

486002 

1 

S10 

HORN BUTTON 

* 

1 

S12 

BRAKE LIGHT SWITCH 

246207 

1 

S13 

FLASHER SWITCH 

* 

1 

S15 

EMERGENCY PUSH BUTTON 

3109800001 

1 

 

EMERGENCY PUSH BUTTON LABEL 

3109800006 

1 

U1 

DC-DC CONVERTER 

* 

1 

X1 

HOUR METER CONNECTOR 

 

1 

X3 

SPEED CONTROL CONNECTOR 

 

1 

X5 

BATTERY CHARGER CONNECTOR 

 

1 

X29 

PVC GROUNDING PLUG, YELLOW 

80003 

 

Y1 

MAIN CONTACTOR 

3104236001 

1 

Y10 

HEATER SOLENOID 

246101 

1 

 

STATIC STRAP 

2450001 

1 

 

* Consult Motrec illustrated parts 

Summary of Contents for E-322

Page 1: ...ur final Les informations et données sont assujetties à des changements sans préavis De plus les photos présentées sont à titre indicatif seulement et pourraient inclure des options non applicables PIÈCES Il est recommandé de valider les numéros de pièces avec Motrec International Inc avant de commander en fournissant le numéro de série du véhicule pour lequel la pièce est requise Dans certains ca...

Page 2: ...E 322 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER 1034667 UP Printed in Canada ...

Page 3: ...ealer 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 featur...

Page 4: ... E 302 E 322 E 330 30 SPARE PARTS 31 BODY 32 CAB 33 DIFFERENTIAL 34 HYDRAULIC DRUM BRAKES 36 HYDRAULIC BRAKE CONTROLS 37 FRONT ASSEMBLY 38 MOTOR AND DRIVE 40 REAR SUSPENSION AND BRAKE 41 ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT 43 DIAGRAMME ÉLECTRIQUE CIRCUIT PRINCIPAL SEPEX 43 ACCESSORIES NO DC DC CONVERTER 44 ACCESSOIRES SANS CONVERTISSEUR DC DC 44 ACCESSORIES DC DC CONVERTER 45 ACCESSOIRES CONVERT...

Page 5: ...Instructions 4 INSTRUCTIONS ...

Page 6: ...ting 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 ...

Page 7: ...ft 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 batteries See HOBBS indicator instructions EMERGENCY SAFETY DEVICE The emergency push button or battery disconnect handle when present should only be used in case of emergency Use the key switch for norm...

Page 8: ...Maintenance 7 MAINTENANCE ...

Page 9: ...tools 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 controller to avoid cracking the terminal or battery post welds Before cleaning or replacing a battery charger speed controller contactor relay diode or any other component in the power circuit always d...

Page 10: ...power 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 speed control failure Before resuming maintenance operations inspect safety warnings stickers and replace any if damage is found and part of the text can t be read Check decals and labels see DECAL AND ...

Page 11: ...on 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 unaltered and readable Else the sticker or the part baring the marking has to be replaced Respectively key switch markings forward reverse selector markings and light switch marking 266211 2819321003 126900...

Page 12: ...istilled water to cover plates 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 BRAKE PEDAL TRAVEL 2 50 mm maximum travel X STEERING FOR PLAY X PARKING BRAKE LEVER requires 30 40 lbs 14 18 kg force to apply X BELTS AND PULLEYS 10 lbs 5kg force for 1 8 ...

Page 13: ...e 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 signal When the micro switch is activated the signal must be less than 50 ohms When the front portion of the pedal is fully depressed the signal must be more than 4600 ohms To modify the resistance turn...

Page 14: ...Maintenance 13 ...

Page 15: ...Maintenance 14 ...

Page 16: ...ble system make sure that cable length is the same at hand lever end tighten ncx3 4 grade 5 bolt in stopper at 8 Lb Ft 11Nm torque cable must extend 1 5 4cm out of the cable stopper cut cable excess Once cable play has been checked and or adjusted turn the knob on the brake lever until a force of 30 40 Lbs or 14 18 kg is required on the handle to set the parking brake Tighten the locking screw BRA...

Page 17: ... from either side Align the front wheel straight Install the pitman arm TOE IN ADJUSTEMENT With the wheels in straight forward direction measure the inside left to right distance between the front tires at the front and rear of the tires Turn the rear tie rod until the distances are equal and tighten the two lock nuts on the tie rod REMOVING GREASING OF FRONT HUBS required once a year Remove dust ...

Page 18: ... 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 areas are thoroughly dry BATTERY LEADS AND CONNECTORS Check for loose connections damaged cables acid spill loose terminal posts quarterly BATTERY POST CORROSION If corrosion is present on battery posts...

Page 19: ... 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 min 4 hours at least every week to equalize battery cells improve battery performance and life in number of cycles Never leave a charger connected for more than 20 hours STORAGE Keep the battery fro...

Page 20: ... 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 polarity Disconnect and check diodes CHARGER OUTPUT IS LOW Disconnect and check diodes Can be caused by a transformer failure AMMETER READS 30 AMPS FOR MORE THAN 30 MINUTES Check the battery pack CHARG...

Page 21: ... 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 the battery gage if not B check wiring Turn the key switch ON check voltage between output terminal on the key switch and the terminal on the battery gage if not B replace the key switch Check voltage...

Page 22: ...esistance 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 following acceleration is not constant maximum speed is erratic sudden stop after a bump or shock erratic starts requiring several pedal cycles A bad F R contactor is also a probable cause of the foll...

Page 23: ...heck 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 wiring and interlock switches Check resistance across power terminals if not 0 ohms replace the solenoid Check circuit breaker and SEPEX DIODE Before replacing the circuit breaker check for shorts in...

Page 24: ...Curtis Speed Controller 23 CURTIS SPEED CONTROLLER 1243 ...

Page 25: ...Curtis Speed Controller 24 ...

Page 26: ...Curtis Speed Controller 25 WIRING STANDARD CONFIGURATION ...

Page 27: ...Curtis Speed Controller 26 DIAGNOSTICS AND TROUBLESHOOTING ...

Page 28: ...Curtis Speed Controller 27 TROUBLESHOOTING CHART ...

Page 29: ...Curtis Speed Controller 28 ...

Page 30: ...Curtis Speed Controller 29 LED DIAGNOSTICS ...

Page 31: ...IN 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 99 0 M4 BRAKE RATE MODE 4 BRAKING RATE IN SEC 2 ADJ HRS MID ADJ HRS MID 0 TO 99 0 INT BRAKE RATE INT BRAKE RATE IN SEC 2 ADJ HRS HIGH ADJ HRS HIGH 0 TO 99 0 QUICK START QUICK START THROTTLE FACTOR 0 S...

Page 32: ...Spare Parts 31 SPARE PARTS ...

Page 33: ...IDE ADJUSTERS 2 120003 TRIMMING 3 2314320001 FRONT BUMPER 5 283001 4 80 X 8 PNEUMATIC WHEEL 5 BOLT 283002 4 80 X 8 FOAMFILLED WHEEL 5 BOLT 2807001 16 O D N M SOFT WHEEL 5 BOLT 6 2382320011 BACKREST CUSHION 7 2803300009 LEFT HANDLE 2809300008 RIGHT HANDLE 8 2352330013 LIFT OUT BATTERY TRAY ...

Page 34: ...PASSENGERS 10 3113000001 WIPER MOTOR 2360320025 LEFT DOOR REAR PASSENGERS 2800000002 WIPER 3 2803000003 PADDLE LATCH 2800000001 ARM 2366320015 DOOR LATCH 11 2366320001 DOOR HANDLE 4 2365000001 RIGHT HINGES KIT 12 2366320002 DOOR HANDLE BAR 2365000002 LEFT HINGES KIT 13 2366320003 DOOR LEVER 5 2367320002 RIGHT DOOR GLASS 14 2367300001 REAR GLASS 2367320001 LEFT DOOR GLASS 15 2367300002 WINDSHIELD 2...

Page 35: ...Spare Parts 34 DIFFERENTIAL ...

Page 36: ...00005 19 Screw Tapping 10 2179300006 20 Vent 1 2179000005 21 Screw Socket Head 8 2179000006 22 Washer Flat 8 2179000007 23 Nut Lock 8 2179000008 24 Seal Oil 2 2104000004 25 Ring Retaining 2 2179000009 26 Assy Bearing Tapered Roller 2 2108000001 27 Seal Oil 2 2104000005 28 Assembly Brake L H 1 2124000001 29 Assembly Brake R H 1 2124000002 30 Shaft Axle L H 1 2173300003 31 Shaft Axle R H 1 217330000...

Page 37: ...R 2 362842 BRAKE SHOE 4 362844 SPRING 5 362845 SPRING 6 362846 SPRING 7 362847 SPRING 8 362848 FITTING 9 362849 BLEEDER 10 362850 PISTON 13 362853 ADJUSTER 14 362855 BOLT GRADE 8 15 3612001 LEFT LEVER 3612002 RIGHT LEVER N A 2123000001 DRUM DANA HOUSING N A 2123360001 DRUM GM HOUSING ...

Page 38: ...1 5 2131100002 Rubber 1 19 2910000007 Clevis 5 16 x 1 1 2 1 6 2131360002 Lever 1 20 2130330001 Handbrake pulling plate 1 7 2133280001 Push rod master cylinder 1 21 2139240002 Handbrake lever 1 8 Hexagonal nut 3 8 16 NF 22 2129000003 Handbrake cable 2 9 2132320001 Pivot 2 23 2129000001 Clip 2 10 Included with 212500001 24 2910000013 Yoke 2 11 2125000001 Master cylinder 1 25 2921000001 Cable stop 2 ...

Page 39: ...Spare Parts 38 FRONT ASSEMBLY ...

Page 40: ...UNEF 18 2134000001 FLEX HOSE 60 2914364001 BUSHING 19 2139000001 CALIPER PROTECTOR 61 2916000001 U BOLT 20 2139000002 WASHER 62 2930000012 GREASE FITTING 21 2139000003 BOLT 63 BOLT 3 8 NC X 1 22 2180240001 SHOCK ABSORBER 64 BOLT 5 8 NC X 4 23 2182320001 SHACKLE LINK 65 BOLT 5 16 NC X 1 1 4 24 2185320001 PLATE 66 BOLT 5 16 NC X 1 25 2185488001 PLATE 67 BOLT 7 16 NC X 2 26 2192280001 LEAF SPRINGS 68...

Page 41: ...D00 SEPEX DC3 SEPEX DD4 SEPEX D D SEPEX MOTOR ASS Y 484000 204050 2450002 2450003 3112210001 3112230001 3112248001 13 BRUSH SPRING 484010 484010 2450006 2450006 2450006 2450006 14 BRUSH PLATE 484011 484011 2450007 2450007 2450007 2450007 16 LEAD ASSY 484017 484017 N A N A N A N A 17 BRUSH 484009 484009 N A N A N A N A 18 LEAD AND BRUSH ASSY N A N A 3112210004 3112210004 3112210004 3112210004 20 DR...

Page 42: ...Spare Parts 41 REAR SUSPENSION AND BRAKE ...

Page 43: ...280001 4 LEAF SPRINGS 18 2192320001 5 LEAF SPRINGS 19 2192320002 7 LEAF SPRINGS HEAVY DUTY 20 2910000017 BOLT LONG 21 2910000018 BOLT SHORT 22 2916000002 U BOLT 1 2 NF X 2 I D 23 2916320001 U BOLT 1 2 NF X 2 3 4 I D or 2916280003 U BOLT 1 2 NF X 3 1 4 I D 24 2916320001 U BOLT 1 2 NF X 2 3 4 I D 25 2916480001 U BOLT 1 2 NF X 4 I D or 2916280003 U BOLT 1 2 NF X 3 1 4 I D 26 BOLT 5 8 NC X 4 27 291000...

Page 44: ...Spare Parts 43 ELECTRICAL DIAGRAM SEPEX MAIN CIRCUIT DIAGRAMME ÉLECTRIQUE CIRCUIT PRINCIPAL SEPEX ...

Page 45: ...Spare Parts 44 ACCESSORIES NO DC DC CONVERTER ACCESSOIRES SANS CONVERTISSEUR DC DC ...

Page 46: ...Spare Parts 45 ACCESSORIES DC DC CONVERTER ACCESSOIRES CONVERTISSEUR DC DC ...

Page 47: ...Spare Parts 46 OPTIONS ...

Page 48: ...TER P1 INDICATOR BDI HOUR METER 1 R1 ACCELERATOR 2142100001 1 PLASTIC GEAR 367015 1 MICROSWITCH 3109100001 1 POTENTIOMETER 367003 1 SPRING 2462008 1 S1 KEY SWITCH 246205 1 S3 SEAT SWITCH 3109000003 1 CONNECTOR 3109000004 S7 FORWARD REVERSE SELECTOR 266211 1 S8 LIGHT SWITCH ROCKER TYPE 1269004 1 LIGHT SWITCH PUSH PULL 486002 1 S10 HORN BUTTON 1 S12 BRAKE LIGHT SWITCH 246207 1 S13 FLASHER SWITCH 1 S...

Page 49: ...Spare Parts 48 BATTERY CONFIGURATIONS 36V CONFIGURATIONS DES BATTERIES 36V ...

Page 50: ...SSEMBLY RELAY 04484S 04484S RELAY TIMER KIT 36 VDC 02028S BUSHING 7W 2 INSULATOR FOR DC CORD 02506S CORDSET AC 14 3 72 11327S CORDSET AC 14 3 18 13895S CORDSET AC 14 3 114 08512S CORDSET DC NO PLUG 12 2 108 12781S CORDSET DC GREY RUBBER PLUG 12 2 108 09522S CORDSET DC NO PLUG 2 10 AWG 160 08020S CORDSET DC WITH LESTER PLUG 08607S CORDSET DC WITH 50 AMP ANDERSON PLUG 08224S CORDSET DC WITH 175 AMP ...

Page 51: ...MER ASSEMBLY RELAY 04484S 04484D RELAY TIMER KIT 36 VDC 02028S BUSHING 7W 2 INSULATOR FOR DC CORD 11923S CORDSET AC 09522S CORDSET DC 2 10 AWG 160 NO PLUG 08512S CORDSET DC NO PLUG 08020S CORDSET DC WITH LESTER PLUG 12781S CORDSET DC WITH GREY LESTER PLUG 08607S CORDSET DC WITH 50 AMP ANDERSON PLUG 08224S CORDSET DC WITH 175 AMP ANDERSON PLUG 10536S CORDSET DC WITH 130 50 AMP EZ GO PLUG 08313S PLU...

Page 52: ...390S CAPACITOR 6 0 MFD 660 VAC 02008S BUSHING 8P 2 INSULATOR FOR DC CORD 02028S BUSHING 7W 2 INSULATOR FOR AC CORD 02506S CORDSET AC 08511S CORDSET DC NO PLUG 18771S CORDSET DC WITH MOLDED PLUG GREY 08067S CORDSET DC WITH LESTER PLUG 08069S CORDSET DC WITH 50 AMP GREY PLUG 08329S CORDSET DC WITH 175 AMP GREY PLUG 20331S CORDSET DC WITH 175 AMP YELLOW PLUG 09434S CORDSET DC WITH 350 AMP GREY PLUG 0...

Page 53: ...LY 19233S 1 CONTROL CABLE ASSEMBLY 02028S 1 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 20924S 1 CORDSET DC 12 2 108 SB 50 PLUG GRAY 20914S 1 CORDSET DC 12 2 108 SB 50 PLUG RED 20926S 1 CORDSET DC 12 2 108 SB 175 PLUG RED 21912S 1 CORDSET DC 12 2 108 SB 175 PLUG GRAY 21408S 1 CORDSET DC 12 2 108 NO PLUG 05322S 2 FUSEH...

Page 54: ...RGER U S BATTERY 3102302001 3102302004 3102302007 36V CHARGER LIFELINE BATTERY 3102302002 3102302005 3102302008 36V CHARGER GEL 180AH BATTRY 3102302003 3102302006 3102302009 48V CHARGER U S BATTERY 3102480002 3102480005 3102480008 48V CHARGER LIFELINE BATTERY 3102480003 3102480006 3102480009 48V CHARGER GEL 180AH BATTERY 3102480004 3102480007 3102480010 72V CHARGER U S BATTERY 3102720001 2 CONNECT...

Page 55: ...Spare Parts 54 ...

Page 56: ...Spare Parts 55 ...

Page 57: ...using 3069012R Bulb 12V 3117240001 Back up lamp Grommet 3269001 12V 3669012 24V 3669012A Clear lamp 12V 3069012 Bulb 12V 1269008 Pedestal head lamp 12V 3111240001 Bulb 12V 2569001B Bulb 24V 2169001B Headlight Left 3111480003 Right 3111480004 Bulb H L 3111480006 Bulb Turn 3111480008 Bulb Mark 3111480007 Headlight Left 3111480003 Right 3111480004 Bulb H L 3117480001 Bulb Turn 3117480003 Bulb Mark 31...

Page 58: ...2V 3113000001 24V 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 light 3669006 12V Fan 3669013 Limit switch 3109000029 Headlamp 12V 3111250007 Headlamp 12V 3111300001 Bulb 12V 3111300002 Red Pilot light 12V 246212 Bulb 12V 246212B Back up alarm or M...

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 K An internal relay can prevent overdischarging and damaging the batteries The relay can be wired to cut off the reverse direction or energize an N C relay and alarm Turning off and on the vehicle w...

Page 60: ...Addendum 59 ADDENDUM ...

Page 61: ...PART NO DESCRIPTION 1 3062001C ACCELERATOR CURTIS 2 367008 POTENTIOMETER 3 2262004C SPRING 4 2262001C MICRO SWITCH 5 2262003C LEVER 6 3662002 CABLE PROTECTOR RESP CLAUDE L MODEL E E 320 360 480 500 NO 321A320001 SER 1018799 TO À 1019973 ...

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