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E-322
WARNING
This manual is for the exclusive use of
dealers accredited by Motrec International
Inc. and should not be considered an
o cial document constituting any kind of
guarantee for the end user. All information
and data are subject to change without
notice. All photos contained in this
document are for illustrative purposes only
and may include non-applicable options.
PARTS:
It is recommended that part numbers be
confirmed with Motrec International Inc.
before ordering by providing the serial
number of the vehicle requiring the part.
In some cases, the part installed on the
vehicle may di er from the manual
depending on the options chosen.
Publication date:
July 1, 2015
Edition for vehicles with
a serial number higher than:
1034667
For additional information,
please contact our customer service:
MOTREC INTERNATIONAL INC.
200 Des PME Street
Sherbrooke, Quebec J1C 0R2
Canada
1-866-846-3558
www.motrec.com
AVERTISSEMENT
Ce manuel est destiné à l'usage exclusif
des concessionnaires accrédités par
Motrec International Inc. et n'est pas
considéré comme un document o ciel
pouvant servir de garantie pour l'utilisateur
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 cas, il
est possible que la pièce installée sur le
véhicule di ère du manuel en fonction
des options choisies.
Date de publication:
1
er
juillet 2015
Édition destinée aux véhicules ayant
un numéro de série supérieur à:
1034667
Pour toutes informations additionnelles,
contactez notre service à la clientèle:
MOTREC INTERNATIONAL INC.
200, rue des PME
Sherbrooke, Québec J1C 0R2
Canada
1-866-846-3558

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Summary of Contents for Motrec E-322

  • Page 1 Motrec International des concessionnaires accrédités par Inc. and should not be considered an Motrec International Inc. et n’est pas o cial document constituting any kind of considéré comme un document o ciel guarantee for the end user. All information pouvant servir de garantie pour l’utilisateur...
  • Page 2 E-322 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER : 1034667 & UP Printed in Canada...
  • Page 3: One Year Limited Warranty

    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.
  • Page 4: Table Of Contents

    BATTERY CHARGER ELECTRICAL TROUBLESHOOTING CURTIS SPEED CONTROLLER 1243 WIRING : STANDARD CONFIGURATION DIAGNOSTICS AND TROUBLESHOOTING TROUBLESHOOTING CHART LED DIAGNOSTICS PROGRAMMING PARAMETERS – E-300, E-302, E-322 & E-330 SPARE PARTS BODY DIFFERENTIAL HYDRAULIC DRUM BRAKES HYDRAULIC BRAKE CONTROLS FRONT ASSEMBLY MOTOR AND DRIVE REAR SUSPENSION AND BRAKE ELECTRICAL DIAGRAM –...
  • Page 5: Instructions

    Instructions INSTRUCTIONS - 4 -...
  • Page 6: Safety Warnings For Operators

    Instructions SAFETY WARNINGS FOR OPERATORS  FAILURE TO OBEY THE FOLLOWING SAFETY RULES MAY 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.
  • Page 7: Operating Instructions

    Instructions OPERATING INSTRUCTIONS It is the responsibility of the owner of this vehicle to ensure that the operator understands the operating characteristics of this vehicle, and obeys the safety instructions in this manual and ANSI/ITSDF B56.8 & 9 Standards. Do not drive this vehicle unless you are a certified operator as required by OSHA. BEFORE TURNING ON KEYSWITCH Set to neutral, set parking brake, check for visible damage, check brake pedal.
  • Page 8: Maintenance

    Maintenance MAINTENANCE - 7 -...
  • Page 9: Safety Warnings For Service Technicians

    Maintenance 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.
  • Page 10 Maintenance Do not try to increase motor speed by changing parameter settings in the speed controller; it can cause accident and severe damage to the motor. SEPEX speed controls are protected by a diode in the power circuit to filter inductive loads in the event of a sudden power interrupt.
  • Page 11: Decals And Labels

    Maintenance 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. Dashboard security warning label: General security warning label: # 5100000002...
  • Page 12: Periodic Maintenance Checklist

    Maintenance PERIODIC MAINTENANCE CHECKLIST FOR MODELS WITH TOWING CAPACITY UP TO 16,000 LB (7270 KG) REVISION 12-01-23 ! WARNING ! Maintenance operations must be made by properly trained service technicians.  Keep clear from moving parts such as tires, sheaves and motor. ...
  • Page 13: Accelerator

    Maintenance ACCELERATOR GEAR  Remove the cover.  Backlash between gears must be reduced to a minimum by sliding holder; use locktite 262 to lock the three screws.  When the plastic gear is fully depressed a small backlash must remain between the gears. ...
  • Page 14 Maintenance - 13 -...
  • Page 15 Maintenance - 14 -...
  • Page 16: Hydraulic & Parking Brakes

    Maintenance HYDRAULIC & PARKING BRAKES FOR MODELS WITH TOWING CAPACITY UP TO 16,000 LB (7270 KG) Revision 2012-01-23 DRUM BRAKES Remove brake drums and check lining wear. Replace shoes and springs if the lining thickness is 1/16" (2mm) or less. Turn the brake adjustment to reduce the clearance between lining and drum. Wheels must turn free when the pedal is released.
  • Page 17: Front Axle And Steering

    Maintenance FRONT AXLE AND STEERING ! CAUTION ! Before maintenance, turn off all switches, set to neutral, set parking brake, remove the key, and raise the front end of the vehicle supporting it with two jack stands of adequate capacity STEERING INSPECTION ...
  • Page 18: Battery Maintenance

    Maintenance BATTERY MAINTENANCE ! WARNING !  It is the responsibility of the owner of this vehicle to ensure that the service technicians are properly trained, read and obey the safety rules and guidelines in this manual (ANSI B56).  Maintenance operations must be made by properly trained service technicians only. ...
  • Page 19 Maintenance BATTERY MOUNTING A loose battery increases damaging effects of vibrations and is more prone to short out. BATTERY DISCHARGE LIMIT Discharging below a 20% state of charge cuts down the battery life and the number of cycles available. At 20% state of charge, specific gravity of 6V battery should be 1180; and 1220 for industrial battery. CHARGING AREA ...
  • Page 20: Battery Charger

    Maintenance BATTERY CHARGER ! WARNING ! Always unplug the AC and DC electrical cords before attempting any repairs to the charger. CHARGER DOES NOT TURN ON:  Dc cord of portable chargers must be disconnected from batteries after every charge to restart; ...
  • Page 21: Electrical Troubleshooting

    Maintenance ELECTRICAL TROUBLESHOOTING ! WARNING ! Maintenance work must be performed by trained service technicians only. It is the responsibility of the owner of this vehicle to ensure that the services technicians are properly trained, understand and obey the safety rules and guidelines (ANSI B56). All service technicians must read and understand the maintenance warning section in this manual.
  • Page 22 Maintenance REVERSE ONLY On a SEPEX motor control, check the forward signal input on the controller. On a series wound motor control, a bad forward contactor is the most probable cause of the problem. Switch to forward and check the voltage on the forward control wire. If not B+, replace the F/R switch. If B+, turn off the key switch, disconnect batteries, disconnect power terminals on the F/R contactors, check the resistance across N.C.
  • Page 23 Maintenance NO MOTION Make sure that the PMC surface is clean and dry; check the terminal areas. Dust Particles or acid contamination, can create current leaks and cause a PMC malfunction. Check F/R switch Turn on the key switch and set to forward. Check voltage between the forward terminal and the –...
  • Page 24: Curtis Speed Controller 1243

    Curtis Speed Controller CURTIS SPEED CONTROLLER 1243 - 23 -...
  • Page 25 Curtis Speed Controller - 24 -...
  • Page 26: Wiring : Standard Configuration

    Curtis Speed Controller WIRING : STANDARD CONFIGURATION - 25 -...
  • Page 27: Diagnostics And Troubleshooting

    Curtis Speed Controller DIAGNOSTICS AND TROUBLESHOOTING - 26 -...
  • Page 28: Troubleshooting Chart

    Curtis Speed Controller TROUBLESHOOTING CHART - 27 -...
  • Page 29 Curtis Speed Controller - 28 -...
  • Page 30: Led Diagnostics

    Curtis Speed Controller LED DIAGNOSTICS - 29 -...
  • Page 31: Programming Parameters - E-300, E-302, E-322 & E-330

    Curtis Speed Controller PROGRAMMING PARAMETERS – E-300, E-302, E-322 & E-330 ! WARNING ! The owner of this vehicle shall ensure that the service technicians are qualified, properly trained and obey the safety rules and guidelines in OSHA and ANSI B56 regulations, and in this manual.
  • Page 32: Spare Parts

    Spare Parts SPARE PARTS - 31 -...
  • Page 33: Body

    Spare Parts BODY PART NO DESCRIPTION 2383320004 SEAT 1005003 BUCKET SEAT ON SLIDE ADJUSTERS 120003 TRIMMING 2314320001 FRONT BUMPER 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 2382320011 BACKREST CUSHION 2803300009...
  • Page 34: Cab

    Spare Parts REF PART NO DESCRIPTION PART NO DESCRIPTION 2360320012 STEEL CAB 2801000002 REAR VIEW MIRROR 2382320009 SEATBACK CAB 2802000001 TRIM DOOR 2360320014 RIGHT DOOR 2801000001 SIDE MIRROR 2360320015 LEFT DOOR 2399000014 SIDE MIRROR BRACKET 2360320024* RIGHT DOOR, REAR PASSENGERS 10 3113000001 WIPER MOTOR 2360320025*...
  • Page 35: Differential

    Spare Parts DIFFERENTIAL - 34 -...
  • Page 36 Spare Parts DESCRIPTION QTY. PART NO. Description Housing, Axle, Service (Inc. 1, 2) 2171300001 Bolt, Bearing Cap 2179300001 Shaft, input 2116300001 Ring, Retaining 2179300002 “O” Ring 2104300002 Bearing, Ball 2102300001 Bearing, Ball 2102300002 Plug, End Cap 2179300003 Bearing, Ball 2102000003 Assembly, Gear, Intermediate 2116300002 “O”...
  • Page 37: Hydraulic Drum Brakes

    Spare Parts HYDRAULIC DRUM BRAKES PART NO DESCRIPTION 362841 PLATE-CYLINDER 362842 BRAKE SHOE 362844 SPRING 362845 SPRING 362846 SPRING 362847 SPRING 362848 FITTING 362849 BLEEDER 362850 PISTON 362853 ADJUSTER 362855 BOLT (GRADE 8) 3612001 LEFT LEVER 3612002 RIGHT LEVER 2123000001 DRUM –...
  • Page 38: Hydraulic Brake Controls

    Spare Parts HYDRAULIC BRAKE CONTROLS PART NO DESCRIPTION REF PART NO DESCRIPTION Hexagonal nut ¼-NC 2910000014 Clevis pin 5/16 x 3/4 2910000015 Yoke 2910000016 Yoke Lock washer ¼ Cotter pin 3/32 x 1 2930000012 Lubrication fitting Flat washer 5/16 2131100002 Rubber 2910000007 Clevis 5/16 x 1-1/2...
  • Page 39: Front Assembly

    Spare Parts FRONT ASSEMBLY - 38 -...
  • Page 40 Spare Parts PART NO DESCRIPTION PART NO DESCRIPTION 2100300002 BUSHING 2208240002 COVER 2100300001 BUSHING WITH OIL SEAL 2219250001 SPACER 2100300003 BUSHING 2224280001 2103250001 THRUST BEARING 2224300002* HUB 2103300001* TAPER BEARING 2229300001 DUST CAP 2103300002* TAPER BEARING 2229300002* OIL SEAL 2103300007 TAPER BEARING 2229300003* SPINDLE WASHER 2104300004...
  • Page 41: Motor And Drive

    Spare Parts MOTOR AND DRIVE COMMON PARTS REF DESCRIPTION PART # DESCRIPTION PART # 1 PULLEY 262424 MOTOR BASE, FORD Contact manuf. 2 V BELT 242431 BELT TENSIONER 2156000012 3 PULLEY 3651001 SEAL 484001 4 BELT, EAGLE 3651002 BEARING 484003 5 MOTOR BASE, GM Contact manuf.
  • Page 42: Rear Suspension And Brake

    Spare Parts REAR SUSPENSION AND BRAKE - 41 -...
  • Page 43 Spare Parts PART NO DESCRIPTION 2120236001 DISC 481431 RIGHT CALIPER 481430 LEFT CALIPER 2121000005 BUSHING, LONG 2121000006 BUSHING, SHORT 2122236001 MOUNTING PLATE, CALIPER 2122300001 LEFT CALIPER SUPPORT 2122300002 RIGHT CALIPER SUPPORT 2128280001 PADS 2128280001 PADS 2129000001 CLIPS 2134000001 FLEX. HOXE 2139000002 WASHER 2139000003...
  • Page 44: Electrical Diagram - Sepex Main Circuit

    Spare Parts ELECTRICAL DIAGRAM – SEPEX MAIN CIRCUIT DIAGRAMME ÉLECTRIQUE – CIRCUIT PRINCIPAL SEPEX - 43 -...
  • Page 45: Accessories - No Dc/Dc Converter

    Spare Parts ACCESSORIES – NO DC/DC CONVERTER ACCESSOIRES – SANS CONVERTISSEUR DC/DC - 44 -...
  • Page 46: Accessories - Dc-Dc Converter

    Spare Parts ACCESSORIES – DC-DC CONVERTER ACCESSOIRES – CONVERTISSEUR DC-DC - 45 -...
  • Page 47: Options

    Spare Parts OPTIONS - 46 -...
  • Page 48 EMERGENCY PUSH BUTTON 3109800001 EMERGENCY PUSH BUTTON LABEL 3109800006 DC-DC CONVERTER HOUR METER CONNECTOR SPEED CONTROL CONNECTOR BATTERY CHARGER CONNECTOR PVC GROUNDING PLUG, YELLOW 80003 MAIN CONTACTOR 3104236001 HEATER SOLENOID 246101 STATIC STRAP 2450001 * Consult Motrec illustrated parts - 47 -...
  • Page 49: Battery Configurations - 36V

    Spare Parts BATTERY CONFIGURATIONS - 36V CONFIGURATIONS DES BATTERIES – 36V - 48 -...
  • Page 50: Built-In Charger Model 6430-00

    Spare Parts BUILT-IN CHARGER MODEL 6430-00 Parts list for LESTRONIC II charger MODEL 06430 TYPE 36LC25-8ET 115 VAC 60 Hz PART NO DESCRIPTION 07335S CASE ASSEMBLY 18687S CASE ASSEMBLY, WITH NO HANDLE 09691S TRANSFORMER ASSEMBLY 02390S CAPACITOR, 6.0 MFD, 660 VAC 16354S HEATSINK ASSEMBLY, WITH DIODES 08776S...
  • Page 51: Portable Charger Model 07710-02

    Spare Parts PORTABLE CHARGER MODEL 07710-02 Parts list for LESTRONIC II charger MODEL 07710 TYPE 36LC25-8ET 115 VAC 60 Hz PART NO DESCRIPTION 07377S CASE ASSEMBLY 07849S TRANSFORMER ASSEMBLY 02390S CAPACITOR, 6.0 MFD, 660 VAC 16354S HEATSINK ASSEMBLY, WITH DIODES 08776S FUSE ASSEMBLY 04127S *...
  • Page 52: Built-In/Portable 40A Charger

    Spare Parts BUILT-IN/PORTABLE 40A CHARGER Parts list for LESTRONIC II charger MODEL 09475 TYPE 36LC40-8ET 115 VAC 60 Hz PART NO DESCRIPTION 09477S CASE ASSEMBLY 09476S TRANSFORMER ASSEMBLY 09041S HEATSINK ASSEMBLY, WITH DIODES 08849S DIODE ASSEMBLY 16823S AMMETER 09685S ELECTRONIC TIMER ASSEMBLY 02390S CAPACITOR, 6.0 MFD, 660 VAC 02008S...
  • Page 53: Built-In/Portable Charger Model 16360-40

    Spare Parts BUILT-IN/PORTABLE CHARGER MODEL 16360-40 Parts list for MODEL 16360-40 TYPE 36EL20-8ET 100-125 or 200-250 VAC / 50-60 Hz PART NO QTY. DESCRIPTION 20952S CASE ASSEMBLY 16365S TRANSFORMER ASSEMBLY 16369S AMMETER 20919S HEATSINK ASSEMBLY, W/ SCR 20948S SCR ASSEMBLY 21475S ELECTRONIC TIMER ASSEMBLY 19233S...
  • Page 54: Delta-Q Hf Charger

    Spare Parts DELTA-Q HF CHARGER DESCRIPTION PART NO PORTABLE PORTABLE BUILT-IN WITH SB-50 WITH SB-350 24V CHARGER ( U.S. BATTERY ) 3102240002 3102240009 3102240013 24V CHARGER ( LIFELINE BATTERY ) 3102240003 3102240010 3102240014 24V CHARGER ( GEL 180AH BATTERY) 3102240004 3102240011 3102240015 24V CHARGER ( 27TM BATTERY )
  • Page 55 Spare Parts - 54 -...
  • Page 56 Spare Parts - 55 -...
  • Page 57: Motrec Illustrated Accessories

    Spare Parts MOTREC ILLUSTRATED ACCESSORIES Red Tail/Brake light Headlight 12V: 386002 Left: 3111480003 Strobe light, pole mount Red Tail/Brake light Right: 3111480004 Amber 12-80V: 3116000002 ** Model EE ** Bulb H/L: 3111480006 Red 12-80V: 2469001 Assembly: 3111000030 Bulb Turn: 3111480008...
  • Page 58 Spare Parts Wiper motor Cab heater 12V: 3113000001 12V: 3103300001 24V: 486211 Analog Voltmeter Headlamp 12V: 3111250007 36V: 3669008 12V : 3069007 48V: 4869020 24V : 2469002 36-48V : 3669002 Headlamp Wiper arm 2800000001 12V Dome light 3669006 12V: 3111300001 HOBBS Gauge Bulb 12V: 3111300002...
  • Page 59: Battery Discharge Indicator (Hobbs)

    Spare Parts BATTERY DISCHARGE INDICATOR (HOBBS) This indicator monitors :  the residual capacity of batteries;  operating hours;  status of service down counter. The residual capacity of the battery is monitored via an 8-LED bar display. When the left red LED lights, the batteries must be charged to avoid damage.
  • Page 60: Addendum

    Addendum ADDENDUM - 59 -...
  • Page 61: Curtis Foot Pedal

    Addendum CURTIS FOOT PEDAL REF. PART. NO DESCRIPTION 3062001C ACCELERATOR CURTIS 367008 POTENTIOMETER 2262004C SPRING 2262001C MICRO-SWITCH 2262003C LEVER 3662002 CABLE PROTECTOR E-320/360/480/500 MODEL(E) : CLAUDE L RESP : 321A320001 1018799 1019973 NO : SER : TO/À : - 60 -...

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