Related Manuals for Motrec E-300
Summary of Contents for Motrec E-300
- Page 1 E-300 OPERATOR AND MAINTENANCE MANUAL SPARE PARTS LISTS INCLUDED SERIAL NUMBER : 1034258 & UP Printed in Canada...
- Page 2 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.
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Page 3: Table Of Contents
CURTIS SPEED CONTROLLER WIRING : STANDARD CONFIGURATION DIAGNOSTICS AND TROUBLESHOOTING TROUBLESHOOTING CHART LED DIAGNOSTICS PROGRAMMING PARAMETERS – E-300, E-302, E-322 & E-330 CURTIS PMC MOTOR CONTROLLER WIRING : STANDARD CONFIGURATION MAINTENANCE AND ADJUSTMENT PMC 1204/1205 TYPICAL ELECTRICAL WIRING SPARE PARTS... -
Page 4: Instructions
Instructions INSTRUCTIONS - 4 -... -
Page 5: Safety Warnings For Operators
Instructions 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. -
Page 6: 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 (ANSI B56). Do not drive this vehicle unless you are a qualified operator. BEFORE USING VEHICLE. -
Page 7: Maintenance
Maintenance MAINTENANCE - 7 -... -
Page 8: 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 ASME/ANSI B56.8 & B56.9 regulations for vehicle maintenance. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust and inspect carriers, vehicles, tractors, and batteries. - Page 9 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.
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Page 10: 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 prior importance that theses decals/markings remain unaltered and readable. Else, the sticker or the part bearing the marking has to be replaced. Dashboard security warning label: General security warning label: Respectively, key switch markings, forward/reverse selector markings and light switch marking:... -
Page 11: Periodic Maintenance Checklist
Maintenance PERIODIC MAINTENANCE CHECKLIST ! WARNING ! Maintenance operations must be made by properly trained service technicians. − Keep clear from moving parts such as tires, sheaves and motor. − Check for all EE protections, when applicable, and keep cables and wires clear from mechanical and rubbing action −... -
Page 12: 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 13: Belt Installation And Tensioning
Maintenance BELT INSTALLATION AND TENSIONING INSTALLATION Adjust the sprockets using a straight edge. Slide up the edge on the larger pulley until it contacts the smaller pulley. Properly adjusted pulleys will provide three points of contact. Properly aligned pulleys will provide four points of contact. Tighten setscrews and recheck alignment. TENSIONING Check the force F required to provide a deflection of 1/8 in. -
Page 14: Hydraulic Brakes
Maintenance HYDRAULIC BRAKES DRUM BRAKES Remove brake drums and check linings wear; the linings should have a thickness exceeding 1/16" (1.5 mm). Turn the brake adjustment to reduce the clearance between lining and drum but avoid contact or drag when the wheels are turned and the pedal is released. DISC BRAKES Check pad linings for excessive wear;... -
Page 15: Mechanical Brakes
Maintenance MECHANICAL BRAKES REPLACING THE BRAKE SHOES − raise the vehicle until the rear tires clear the floor and install two jack stands on rear; − disassemble and clean the adjusting screw assembly; − check brake lever for wear; − replace all spring parts; −... -
Page 16: 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 17: 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 18 Maintenance Frequency of charge. − Always charge battery in a well ventilated area set for and approved for charging. 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.
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Page 19: Battery Charger
Maintenance BATTERY CHARGER ! CAUTION ! Always unplug the AC and DC electrical cords before attempting any repairs to the charger. CHARGER DOES NOT TURN ON: − Dc output cord of portable chargers must be disconnected from batteries after every charge to restart;... -
Page 20: 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 21 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 22 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 –...
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Page 23: Curtis Speed Controller
Curtis Speed Controller CURTIS SPEED CONTROLLER - 23 -... - Page 24 M A N U A L 1 2 4 3 Generation 2 MultiMode™ MOTOR CONTROLLER © 2002 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS PMC 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. CURTIS INSTRUMENTS, INC. 200 Kisco Avenue 1243 2 Manual, p/n 37044 Mount Kisco, NY 10509 USA Rev.
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Page 25: Wiring: Standard Configuration
2 — INSTALLATION & WIRING: Controller for the M8 bolts. The maximum bolt insertion depth below the surface of the bus bar is 1.3 cm (1/2"). B olt shafts exceeding this length may damage the controller. The torque applied to the bolts should not exceed 16.3 N·m (12 ft-lbs). Two 1/4"... -
Page 26: Diagnostics And Troubleshooting
7 — DIAGNOSTICS & TROUBLESHOOTING DIAGNOSTICS AND TROUBLESHOOTING The 1243 2 controller provides diagnostics information to assist technicians in troubleshooting drive system problems. The diagnostics information can be obtained by observing the appropriate display on the handheld programmer, the fault message displayed on the S pyglass gauge, the fault codes issued by the S tatus LED, or the fault display driven by the controller’s fault outputs (Fault 1 and Fault 2). -
Page 27: Troubleshooting Chart
7 — DIAGNOSTICS & TROUBLESHOOTING Table 7 TROUBLESHOOTING CHART PROGRAMMER FAULT CODE LCD DISPLAY CATEGORY POSSIBLE CAUSE FAULT CLEARANCE NO KNOWN FAULTS CURRENT SHUNT FAULT 1. Abnormal vehicle operation causing Cycle KSI. If problem high current spikes. persists, replace controller. 2. - Page 28 7 — DIAGNOSTICS & TROUBLESHOOTING Table 7 TROUBLESHOOTING CHART, cont’d PROGRAMMER FAULT CODE LCD DISPLAY CATEGORY POSSIBLE CAUSE FAULT CLEARANCE LOW BATTERY VOLTAGE 1. Battery voltage < undervoltage cutback. When voltage rises above 2. Corroded battery terminal. undervoltage cutoff point. 3.
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Page 29: Led Diagnostics
7 — DIAGNOSTICS & TROUBLESHOOTING STATUS LED DIAGNOSTICS A Status LED is built into the 1243 2 controller. It is visible through a window in the label on top of the controller. This Status LED displays fault codes when there is a problem with the controller or with the inputs to the controller. -
Page 30: 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 31: Curtis Pmc Motor Controller
Curtis Speed Controller CURTIS PMC MOTOR CONTROLLER - 31 -... - Page 32 M A N U A L 1204/5 MOTOR CONTROLLERS © 1999 CURTIS INSTRUMENTS, INC. DESIGN OF CURTIS 1200 SERIES CONTROLLERS PROTECTED BY U.S. PATENT NO. 4626750. CURTIS PMC 235 East Airway Boulevard 1204 / 1205 Manual Livermore, California 94568 USA p/n 98690, Rev.
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Page 33: Wiring : Standard Configuration
W IRIN G WIRING CONNECTIONS: Low Current Three 1/4" push-on terminals are provided throttle for the low current connections to the KSI inputs and throttle inputs. For the control wiring, 0.75 mm (#18 AWG) vinyl insulated stranded wire is rec- ommended. - Page 34 WIRING CONTROL WIRING PEDAL KEYSWITCH INTERLOCKS FUSE MICROSWITCH POLARITY PROTECTION DIODE POWER WIRING MAIN FUSE PRECHARGE RESISTOR (250 Ω, 5 W) POTBOX – Fig. 6 Basic wiring configuration, Curtis PMC 1204/1205 controller. WIRING: SERIES MOTORS Figure 6 is a schematic of the configuration shown in Figure 5. Wired this way, the vehicle will plug brake if the direction is changed with the vehicle moving and the throttle applied.
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Page 35: Maintenance And Adjustment
MAINTENANCE & ADJUSTMENT MAINTENANCE & ADJUSTMENT Curtis 1204/1205 controllers and potboxes require only minimal main- tenance if properly installed. : The controllers are sealed and thus NOTE are not field serviceable. CONTROLLER Maintenance It is recommended that the following two steps be performed occasion- ally. - Page 36 MAINTENANCE & ADJUSTMENT Adjustment On some models, the plug braking current and acceleration rate settings are adjustable. On these adjustable controllers, the adjustment pots are located as shown in Figure 18. Fig. 18 Adjustment pots. ACCELERATION RATE ADJUST PLUG CURRENT ADJUST (CW = higher plug current) (CW = faster acceleration) Use the following adjustment procedure.
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Page 37: Pmc 1204/1205 Typical Electrical Wiring
Curtis Speed Controller PMC 1204/1205 TYPICAL ELECTRICAL WIRING - 37 -... -
Page 38: Spare Parts
Spare Parts SPARE PARTS - 38 -... -
Page 39: Body
Spare Parts BODY PART NO DESCRIPTION REF PART NO DESCRIPTION 1005003 BUCKET SEAT ON SLIDE ADJUSTER 2360300004 3005003 SEAT (NOT ILLUSTRATED) 2360300005 RIGHT DOOR 3605008 SEATBACK (NOT ILLUSTRATED) 2360300006 LEFT DOOR 2380300003 SEAT PLATE 2803000003 PADDLE LATCH 2384320009 BACKREST 3602024 CATCH 2333300001 FRAME DECK 2366320001... -
Page 40: Differential And Mechanical Drum Brakes
Spare Parts DIFFERENTIAL AND MECHANICAL DRUM BRAKES - 40 -... - Page 41 Spare Parts REF. PART NO DESCRIPTION 2173300001 SHAFT, 5-BOLT 242053 LOCK 2910000001 BOLT 242056 OIL SEAL before serial # 0611200 2420011 OIL SEAL after serial # 0611201 2420010 BEARING 242058 242059 WASHER 262081 PULLEY 12" O.D. 242060 OIL SEAL 242061 TAPER BEARING 382062 HOUSING before # serial 0611200...
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Page 42: 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 - 42 -... -
Page 43: Mechanical Drum Brakes
Spare Parts MECHANICAL DRUM BRAKES MANUAL ADJUSTEMENT, OLD SELF ADJUSTEMENT, NEW SERIAL NUMBER 0707070 & + REF. PART NO DESCRIPTION REF. PART NO DESCRIPTION 242051 DRUM 2413001 DRUM 4-BOLT BOLT, 5/16-NC X 3/4 2123240001 DRUM 5-BOLT 242841 BACK PLATE 2413002 BACKING PLATE LH 242842 BRAKE SHOE... -
Page 44: Brake Controls - Drum Brake
Spare Parts BRAKE CONTROLS – DRUM BRAKE PART NO DESCRIPTION REF PART NO DESCRIPTION 242800 RUBBER PEDAL CLEVIS PIN 3/8 X 1 242802 LATCH 2130300001 ROD 242803 382836 2416008 CLEVIS PIN ¼ X 2 362833 Clip 122813 YOKE 362832 CLIP 242806 SPRING 3016019... -
Page 45: Hydraulic Brake Controls
Spare Parts HYDRAULIC BRAKE CONTROLS PART NO DESCRIPTION REF PART NO DESCRIPTION 242800 Rubber 3616013 8 in. Handbrake lever 2190000003 Spring 362831A Cable 2131300002 Lever 362832 Clip 382831 Pivot 362833 Cable stop 242817 Lubrication fitting 3616014 Handbrake band (cable side) Clevis pin 3/8 x 1 3616012 Handbrake band... -
Page 46: Front Assembly
Spare Parts FRONT ASSEMBLY - 46 -... - Page 47 Spare Parts PART NO DESCRIPTION PART NO DESCRIPTION 2208240001 STEERING WHEEL 3040002 PLATE 481452 NUT 3/4-16 BOLT 3/8-NC X 4 481453 COVER 3040001 PLATE 481454 BOLT: 481457 BUSHING 481434 LONG 481458 TUBE 481442 SHORT ROD END: 481440 BOLT 2207000001 LEFT HAND 481441 WASHER 2207000002 RIGHT HAND...
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Page 48: Motor And Drive
Spare Parts MOTOR AND DRIVE COMMON PARTS DESCRIPTION PART # DESCRIPTION PART # 1 PULLEY 262424 8 MOTOR BASE, FORD Contact manuf. 2 V BELT 242431 BELT TENSIONER 2152002 3 PULLEY 3651001 9 SEAL 484001 4 BELT, EAGLE 3651002 10 BEARING 484003 5 MOTOR BASE, GM Contact manuf. -
Page 49: Electrical Diagram - Sepex Main Circuit
Spare Parts ELECTRICAL DIAGRAM – SEPEX MAIN CIRCUIT - 49 -... -
Page 50: Electrical Diagram - Series Main Circuit
Spare Parts ELECTRICAL DIAGRAM – SERIES MAIN CIRCUIT - 50 -... -
Page 51: Accessories - No Dc/Dc Converter
Spare Parts ACCESSORIES – NO DC/DC CONVERTER - 51 -... -
Page 52: Accessories - Dc-Dc Converter
Spare Parts ACCESSORIES – DC-DC CONVERTER - 52 -... -
Page 53: Options
Spare Parts OPTIONS - 53 -... - Page 54 247002 FORWARD/REVERSE SELECTOR 266211 LIGHT SWITCH, ROCKER TYPE 1269004 HORN BUTTON BRAKE LIGHT SWITCH 246207 FLASHER SWITCH DC-DC CONVERTER HOUR METER CONNECTOR MAIN CONTACTOR 366222 Y2-Y3 F/R CONTACTOR 366217 STATIC STRAP 90330 * Consult Motrec illustrated parts - 54 -...
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Page 55: Batteries Configurations - 36V
Spare Parts BATTERIES CONFIGURATIONS - 36V - 55 -... -
Page 56: 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 57: 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 58: 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 59: 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 60: Motrec Illustrated Accessories
Spare Parts MOTREC ILLUSTRATED ACCESSORIES Headlight Red Tail/Brake light Left: 3111480009 Strobelight, polemount Housing: 3069012R Horn button VIP Right: 3111480010 Amber 12-80V: 3116000001 Bulb 12V: 3117240001 2330014 Bulb H/L: 3111480011 Red 12-80V: 2469001 Bulb Turn: 3111480012 Blue 12-80V: 3690008 Bulb Mark:... - Page 61 Spare Parts Wiper arm 2800000001 Cab heater DC-DC converter, 10A 12V: 3103300001 12-48V: 3069019 Headlamp 12V: 3111250001 36V: 3669008 48V: 4869020 Wiper blade DC-DC Converter, 25A 14” Blade: 2800000001 12-48V: 3124000002 18” Blade: 2800000002 72-80V: 3124720001 Headlamp 12V Dome light 3669006 12V: 3111300001...
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Page 62: 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 63: Curtis Foot Pedal
Spare Parts CURTIS FOOT PEDAL REF. PART. NO DESCRIPTION 3062001C ACCELERATOR CURTIS 2262002C POTENTIOMETER 2262004C SPRING 2262001C MICRO-SWITCH 2262003C LEVER 3662002 CABLE PROTECTOR E-320/360/480/500 CLAUDE L RESP : MODEL(E) : 321A320001 1018799 1019973 NO : SER : TO/À : - 63 -...