Motrec E-322, Operator And Maintenance Manual

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Maintenance
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SAFETY WARNINGS FOR SERVICE TECHNICIANS
FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAIN RESULT IN SEVERE INJURY.
Owner shall comply with OSHA and ANSI/ITSDF B56.8 & B56.9 Standards for vehicle maintenance.
Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect
carriers, vehicles, tractors, and batteries.
Before any maintenance work, park the vehicle on flat level surface, turn off all switches, remove key,
lift wheels off the ground and secure with jack stands of adequate capacity. Don’t connect charger.
Keep clear from moving parts such as tires, sheaves and motor.
Follow the maintenance instructions applicable to the type of repair, maintenance, or service.
Always wear a face shield and gloves when working around batteries.
Before opening the battery compartment, disconnect the charger, turn off all switches and remove the
key. Batteries emit highly explosive gases which greatly increase when charging; do not disturb
connections or produce sparks around batteries to avoid a battery explosion and acid splashing. Battery
acid causes severe damage to eyes or skin. Flush contaminated area immediately with water.
Use insulated 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 disconnect the charger, turn off all switches, remove the key,
wear a face shield and gloves, identify battery polarity and disconnect battery leads, discharge the
capacitor in the controller with a 10 ohms, 25 W resistor for a few seconds across B+ and B-.
After cleaning, the power must not be reapplied until terminal areas are thoroughly dry.
On EE-Rated vehicles make sure that the control box is sealed, the static strap makes good contact with
the ground, the motor is sealed by bands, the cable protectors are properly installed.
Keep cables and wires clear from mechanical and rubbing action. Make sure that cable insulation is
free from cutting or visible damage. Make sure that EE-Rated cable protectors are properly installed.
Before replacing a fuse or circuit breaker, identify the cause of failure and repair.
Programmable controllers must be programmed using the parameter settings in this service manual,
before connecting the motor, to avoid sudden vehicle movement and accident.