Columbia ParCar Expediter EX21-24A, Service Manual

Page: 93 / 94

Section 10 – Traction Drive System
ensure connections are correct. Figure 10-18
4. F1 and F2 terminals are 1/4-20 while A1 and A2 terminals
are 5/16-18. Attach cables with flat washers, lock washers
and hex nuts. Torque A1 & A2 cable attaching nuts to 110
in. lbs. (12.4 N m), while holding the bottom nut, with a thin
open-end wrench. Torque F1 & F2 cable attaching nuts to
50 in. lbs. (5.7 Nm), while holding the bottom nut, with a
thin open end wrench.
5. Place vehicle on the ground or onto dynamometer to test
motor operation.
Do not run motor at full voltage without a load.
CONTROLLER
ACEplus SYSTEM
The ACE plus System is an advanced traction drive system that
uses a fully integrated, solid state Sevcon Controller for speed
regulation and forward/reverse control. Combined with a
separately excited DC motor, the system provides optimized
power efficiency through pedal proportional speed control and
regenerative braking. This control system is ideal for hilly terrain
or areas with multiple ramps. It is also used for towed loads and
high braking demands. The ACE
plus system is distinguished
by a 6 post controller. See Figure 10-19.
TESTING
Do not remove the controller. It can be tested while still in the
Vehicle.
1. Look for the steady green light on the side of the controller.
If it is on, the system is OK and ready (Figure 10-20).
2. If it is flashing, count the number the flashes in each
sequence. Refer to Section 4 - Troubleshooting for
controller flash troubleshooting info, and for info on testing
controller with Sevcontrol Calibrator or PC Pak computer
interface.
3. If the tests indicate that the controller has failed, replace it.
REMOVING
1 Disconnect battery negative cable and remove Power key.
2. Label/mark controller cables with controller terminal
identification, if not already labeled.
NOTICE: The controller terminal bolts and washers are
Metric. Metric wrenches are required to remove the
controller cable fasteners. The fasteners that attach the
controller to the vehicle frame are SAE U.S.
3. Remove six metric bolts, lock washers, flat washers and all
the cables and wires connected to the controller.
4. Remove 16 pin controller connector (Figure 10-20).
Figure 10-20
5. Remove four nuts, washers and bolts securing controller to
the mounting panel.
NOTICE: Do not attempt to disassemble the controller.
There are no repairable parts inside.
See Columbia Service Bulletin 06-010 if the wiring harness or
connector s are damaged.
INSTALLING
1. Position controller mounting panel and secure with four
bolts, washers and nuts.
2. Install cables to controller terminals according to cable
identification labels. Make sure there is a flat washer under
the terminal ends of the cables. This will spread the load
and help prevent the terminal ends from folding over. 3.
Torque controller cable attaching bolts to 50
– 60 in. lbs.
Figure 10 - 19
MOUNTING BOLTS
GREEN LIGHT
PIN CONNECTOR 16