Columbia Journeyman Series Maintenance Manual Download Page 91

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Electric Component

9-11

Chapter 9

6. Remove the DC converter.

DC converter installation

Back to the removal steps.

Summary of Contents for Journeyman Series

Page 1: ...Maintenance Manual ...

Page 2: ...and other products are subject to improvement that may influence the maintenance procedure with no notice nor obligation to alternate devices sold previously Before starting any service on the electric vehicle read the Manual carefully and note the difference of the following symbols This indicates Note Alarm Watch your safety WARNING The symbol indicates a danger may occur calling the attentions ...

Page 3: ...ly and Assembly 1 7 Chapter 2 Regular Inspection and Adjustment Regular Maintenance 2 1 Periodic Lubrication Plan 2 3 Braking System 2 4 Braking Inspection 2 4 Inspection of Brake 2 5 Inspection of Brake Drum and Brake Shoe 2 6 Inspection of the Accelerator Pedal 2 9 Inspection of the Steering System 2 9 Inspection of the Steering Linkage 2 10 Inspection of Stub Axle 2 11 Inspection of the Front W...

Page 4: ...hion 4 2 Remove 4 2 Install 4 3 Removal of Front Cover 4 4 Remove 4 4 Install 4 4 Removal of the Dashboard 4 4 Remove 4 4 Install 4 5 Removal of the Rear Cover 4 6 Remove 4 6 Install 4 6 Rear cover 4 9 Chapter 5 Front Axle Front axle 5 1 Removal of the Front Axle 5 2 Remove 5 2 Inspect 5 6 Install 5 7 Chapter 6 Driving Axle Driving axle 6 1 Removal of the Driving Axle 6 2 Remove 6 2 Inspect and te...

Page 5: ...tion switch removal 9 5 Combination switch installation 9 5 Controller removal 9 6 Controller installation 9 6 Charger receptacle removal 9 9 Charger receptacle installation 9 9 Battery removal 9 10 Battery installation 9 10 DC converter removal 9 10 DC converter installation 9 10 Motor removal 9 12 Motor installation 9 13 Removal of bulb of headlight and front turn signal light 9 14 Headlight ins...

Page 6: ...heck Procedure 7C Pin 3 and 4 10 8 Check Procedure 7D Pin 7 and 8 10 9 Check Procedure 7E Pin 9 10 9 Check Procedure 8 Motor speed sensor 10 10 Check Procedure 9 forward r everse switch 10 11 Check Procedure 10 Reverse buzzer 10 11 Check Procedure 11 Battery discharge meter 10 12 Check Procedure 12 High mount stop lamp 10 13 Check Procedure 13 wiper 10 13 Troubleshooting Instructions Part 2 10 14 ...

Page 7: ... Hydrometer inspection result presentation 11 11 Discharge test 11 12 Procedures for discharge test 11 13 Discharge test result presentation 11 13 Battery troubleshooting example 11 14 Battery storage 11 15 Battery charger 11 16 Overview 11 16 Conditions to be noted before charging 11 16 Get to know the charger 11 17 Removal of the charger 11 18 Maintenance of the battery charger 11 19 Troubleshoo...

Page 8: ...8 ...

Page 9: ...cleaned on a regular basis and be handled properly Safe Use of Battery Before maintenance the battery acid should be sealed The battery can give off explosive gases The battery should be kept away from the ignition source The liquid level of electrolyte should be inspected with the use of flashlight Do not measure and test the voltage after connecting the battery wire A voltmeter or hydrometer sho...

Page 10: ...idents Vehicle Safety During Maintenance The parking brake should be applied Blocks should be placed in front of the front tires No one should be allowed to stand in front of or behind the vehicle being serviced Electrical Safety During Maintenance DANGER Battery contains explosive gas Smoking is strictly prohibited Sparks and open flames should be kept away from the electric vehicle and the worki...

Page 11: ...rks contained in this Manual and attached to the electric vehicle Misuse of electric vehicles or inappropriate maintenance may result in the performance degradation of the vehicle or serious personal injury Any refit or alteration of the electric vehicle that may affect its stability or maneuverability or any speed increase beyond the maximum speed specified in the manufacturer s specifications ma...

Page 12: ...tion of this warning may result in serious burns While working beside the battery or electrical element the operator should use insulated tools with special care to avoid short circuit of the component or wiring Before servicing the electric vehicle please turn the key switch to the OFF position and take the key out Turn FWD REV switch to NEUTRAL position and chock the wheels with blocks ...

Page 13: ...fting Jack Front put the lifting jack below the pivot to support it Rear Use the portion of crossed frames Caution In the case that the lifting jack is placed behind the vehicle the lifting jack should be prevented from touching the back tower bar To avoid unintentional start up of the electric vehicle please assure that the E Brake switch at the middle position Normal After disconnection of the b...

Page 14: ...strumentation for Electric Control System 1 Pocket detector This device is of vital importance to the inspection of the electrical control system 2 Hydrometer This instrument is designed to measure the precise specific grayte of the electrolyte Cautions Washing and Cleaning Before the maintenance thoroughly clean the body and exterior of the components During the cleaning care should be taken to p...

Page 15: ...aring and oil seals on which the manufacturer s mark and number are present the mark and number should face outwards for easy identification All the bearing and oil seals once removed must be replaced with new ones To apply the oil seal cover a thin layer of light lithium grease over the oil seal While mounting the bearing the lubricants should be fully applied Recommendations on Disassembly and A...

Page 16: ... kilometers Every two years 18600 miles 30000 kilometers Every three years Charging S S S S S Clean the top of the battery and inspect the retaining screws and terminals for tightness S S S S S Inspect the brake pedal for free travel and make adjustments when necessary C CA CA CA CA Inspect the operation of the steering wheel C C C C C Inspect the tire pressure and the tire recession and tread for...

Page 17: ... the rear axle bearing for normal operation C C C Inspect the steering knuckle bushing for normal operation Adjust front wheel alignment CA CA CA Inspect the nuts of the wheel for tightness and the front wheel bearing for normal operation C C C Replace the lubricating oil in the gear box R Annual inspection Inspect the parking pedal for free travel and make adjustments when necessary CA CA CA Insp...

Page 18: ...ptacle 4 NYE760G Front suspension 4 3 Lithium based grease Front stub axle Lithium based grease The user or trained technician applies the lubricating oil once a quarter every 50 working hours Braking grease cup 8 DOT4 4000 brake oil Inspect the driving axle oiled cork position Gear oil SAE 80 0 8 liter The trained technician applies the lubricating oil once a year every 100 working hours Inspect ...

Page 19: ...g the body 2 Inspect Brake master cylinder Brake Oil Pipeline Tee joint Front wheel brake caliper Oil leakage if any replacement is required Front wheel brake shoe Standard thickness 7 0 mm 0 28 in Maximum wear value of thickness 2 5 mm 0 1 in Brake disc Standard thickness 4 0 mm 0 16 in Maximum thickness wear value 1 0 mm 0 04 in Damaged defective one is to be replaced ...

Page 20: ...Inspection and Adjustment 2 5 Chapter 2 3 Measure Free play of the brake pedal Push against the pedal by hand slightly and measure the distance it travels before the pressure is lost Defects are to be replaced ...

Page 21: ...ire lug nuts and then the rear wheels 4 Loosen the brake drum and knock slightly on the drum with mallet 5 Inspect Internal surface of the brake drum Oil fully clean until no oil is found Scrape Rub lightly with the abrasive cloth Brake wheel cylinder Where the upstream assembly is in normal working condition step on the brake pedal In case the brake wheel cylinder cannot open the brake shoe or oi...

Page 22: ... wearing value of the inside diameter 1 5mm 0 06 in 7 Inspect Surface of shoe block Oil Replace the old one or fully clean until no oil is found Scrape Rub lightly with the abrasive cloth 8 Measure the thickness of the shoe plate and replace the shoe plate that does not meet the specifications or in case brake shoe block is too old Standard thickness 4 0 mm 0 09in Maximum thickness wearing value 1...

Page 23: ... on the surface of the brake drum and shoe block 10 Install Wheel nuts Tightening torque to 90N m 66 4ft 1b NOTICE First screw on the wheel nuts by hand and then tighten the nuts diagonally 11 Upon the completion of the installation step on the brake pedal about 10 times to adjust the clearance between the shoe plate and the drum ...

Page 24: ...case the free play is too loose Limit value to the free pedal travel 95mm 3 74in measured at the top of the pedal Inspection of the Steering System State of the Steering Wheel in Steering Operation 1 Inspect Steering clearance Push and pull or turn the steering wheel In case of over looseness the steering wheel or cross pin type joint bolts should be tightened Limit value to steering clearance of ...

Page 25: ... Re inspect Steering clearance Inspection of the Steering Linkage Removal of Tie Rod Ball Joint 2 Inspect Ball joints in the following conditions Unsteady operation Over loose free operation Bending or scrape Damage of dust boot Refer to Chapter 8 Steering System NOTICE In case of any of the above conditions replace with a new ball joint 3 Install Steering Gearbox ball joint ...

Page 26: ...adjusted Inspection of the Front Wheel Alignment Toe in 1 Park the vehicle on flat surface 2 Push the vehicle straightly ahead for about 20 steps to stabilize the suspension NOTICE Do not pull back the vehicle or step on the brake pedal as it will leads to changing of toe in 3 Measure Toe in Empty 5 8mm 0 20 0 32in Full load 0 3mm 0in 0 118in In case of non compliance with standard specified adjus...

Page 27: ...decrease Tighten the locknut on the drag link ball joints Tightening torque to 40N m 29 5ft 1b Inspection of Tires and Wheel Rim 1 Measure Air pressure In case of non compliance with the standard adjustment is to be made Tire pressure front and rear tires 200 220kPa Inspect Tire surface In case of any abrasion damage scrape or inset the tire is to be replaced Wheel rim In case of any damage or def...

Page 28: ...ain Shaft being touched In case the clearance is too large replace the bearing Inspection of the Rear Axle Bearing 1 Wedge blocks on the front lower part of the front wheels and loosen the rear wheel bolts 2 Lift the rear body with the lifting jack 3 Remove Rear wheels Brake drum 4 Slowly rotate by hand the half shaft of rear axle In case of unsmooth or unsteady rotation the bearing is to be repla...

Page 29: ...replacement of a new rear axle half shaft assembly Inspection of the Shock Damper 1 Inspect For oil leakage In case of oil leakage the shock damper is to be replaced Spring In case of decay scrape or damage the shock damper is to be replaced Mounting bolts of front shock damper Tightening torque 63N m 46 5ft 1b Mounting bolts of the rear shock damper Tightening torque 63N m 46 5ft 1b ...

Page 30: ...eize the belt The belt when loosened should be retracted back into the retractor Otherwise the seat belt assembly is to be replaced with new one 2 Seat Belt Buckle Buckle the seat belt and pull with force the belt near the buckle to verify if the buckle can hold the belt securely NOTICE In case of damage scrape insensitive reaction the seat belt assembly is to be replaced with a new one ...

Page 31: ...ts of the canopy 3 Canopy Install Canopy In the reverse order of the removal procedures Tightening torque 9N m 6 6ft 1b Removal of Canopy Rods Remove 1 Fixing bolt on the rear pillar 2 Fixing bolt on the center pillar E 4 3 Install slip bolt 4 Canopy rod 5 Fixing bolt of front canopy rod 6 Front canopy rod ...

Page 32: ...s Tightening torque for 22N m 16 2 ft 1b Removal of the Pillar Remove 1 Fixing bolt of backrest bracket 2 Backrest bracket 3 Fixing bolt on the rear pillar 4 Fixing bolt on the rear pillar branch 5 Rear pillar 6 Rear pillar branch 7 Fixing bolt on the center pillar connector E 4 8 Center pillar connector 9 Fixing bolt on the center pillar E 4 10 Center pillar ...

Page 33: ...Canopy 3 3 Chapter 3 Install Pillar In the reverse order of the removal procedures Tightening torque 22N m 16 2 ft 1b Tightening torque for 22N m 16 2 ft 1b Tightening torque 30N m 22 1 ft 1b ...

Page 34: ...er 2 Removal of the Rear Tray Remove Rear box cover Rubber nail Screw Rear tray Clamping nut 3 Removal of the Rear Bumper Remove Bolt Rear bumper bracket Bolt Rear bumper Install Front bumper In the reverse order of the removal procedures Tightening torque 63N m 46 5 ft 1b ...

Page 35: ... of the Seat Cushion Remove 1 Removal of the seat cushion Handrail fixing bolt Handrail Handrail bracket fixing bolt Handrail bracket Upper hinge fixing bolt Upper hinge Bolts on seat cushion bottom plate Seat cushion Bottom plate of seat cushion 2 E 2 Removal of the Backrest Bolt Backrest 3 2 2 Series Backrest Removal Bolt Rear seat backrest Bolt ...

Page 36: ...t Tightening the torque of bolt 22N m 16 2 ft 1b Rear seat backrest 2 2 series Tightening the torque of bolt 22N m 16 2 ft 1b Seat cushion Bottom plate of seat cushion Bolts on seat cushion bottom plate Handrail bracket Handrail bracket fixing bolt Tightening torque 22N m 16 2 ft 1b ...

Page 37: ...age 3 1 Instrument panel Plastic nail on the upper dashboard Fixing nuts on the lower dashboard Tightening torque 22N m 16 2 ft 1b Fixing bolt on the lower dashboard 2 Remove Front cover nuts Tightening torque 9N m 6 6 ft 1b Front cover bolts 3 Remove Front cover Install In the reverse order of the removal procedures ...

Page 38: ...the lower dashboard 3 Disconnect Connecting line of main switch Connecting line of coulomb meter Steps connecting line Connecting line of multi functional receptacle Plug in modules of combination switch connecting line 4 Remove Dashboard Combination switch 5 Disengage the clasp and remove the cup holder 6 Disengage the clasp and remove the baffle 7 Remove Fixing bolts 2 on the Turn Singal Stalk b...

Page 39: ...ering wheel nuts 50N m 36 9ft 1b Removal of the Rear Cover Remove 1 Remove Seat cushion Seat backrest Pillar NOTICE Refer to Removal of Seat Cushion on page 4 3 Refer to Removal of Pillar on page 3 2 2 Remove Rear box cover Plastic nail Screw Rear tray Refer to Removal of Rear Tray on page 4 1 3 Disconnect Rear light connecting line ...

Page 40: ...g bolts of lower hinge Tightening torque 7N m 5 2 ft 1b Hinge Rear cover bolt Tightening torque 9N m 6 6 ft 1b 5 Remove Rubber nail of rear cover plate Rear cover plate Rear cover Install In the reverse order of the removal procedures ...

Page 41: ...r box cover 4 Tray 5 Left rear light 6 Right rear light 7 On board charging plug box 8 Left ventilating window 9 Right ventilating window 10 Lower hinge 11 Rubber nail 12 Screw 13 Nut 14 Large pan head bolt 15 Nut 16 Screw 17 Rubber nail 18 Rubber cover of rear pillar ...

Page 42: ...ng 9 Lower lug shaft 10 Hub connected plate 11 Large dust cover 12 Wheel nuts 13 Slotted nut 14 Split pin 15 Wheel rim decorative cover 16 Front wheel 17 Front wheel rim 18 Inside spacer of Spindle 19 Slotted nut 20 Nut 21 Upper bush 22 Lower bush 23 Bolt 24 Bolt 25 Dust cover 26 Nylon bush 27 Inside spacer of swing arm 28 Air valve 29 Upper lug 30 Bolt ...

Page 43: ...el 6 Inspect The operation of wheel bearing Rotate the hub connected plate by hand In case of unsmooth operation the bearing is to be replaced with new one 7 Inspect Free gap of wheel bearing Swing the hub back and forth In case the free gap is too large the slotted nut is to be tightened In case the clearance is still too large the bearing is to be replaced with new one 2 Assure that the E Brake ...

Page 44: ...er 5 8 Remove Dust cover 9 Remove Split pin Slotted nut 10 Remove Brake tongs bolt Tightening torque 23N m 17 0 ft 1b Brake tongs 11 Remove Hub connected plate of front wheel Knock at the connected plate with a soft hammer ...

Page 45: ...m 0 16 in Maximum wearing thickness 1 mm 0 04 in 13 Remove Bolt Tightening torque 23N m 17 0 ft 1b Fore wheel brake shoe Standard thickness 7 mm 0 28 in Maximum wearing thickness 1 mm 0 04 in 14 Inspect Spindle free gap Swing the Spindle In case the free gap is fairly large the inside spacer and bush of the Spindle are to be replaced ...

Page 46: ...val of Drag Link Ball Joint Split pin Pivot slotted nut Spindle lug Spindle Inside spacer of Spindle Bush of Spindle 16 Inspect Free gap of swing arm Swing the swing arm In case the free gap is fairly large the inside spacer and nylon bush of the swing arm are to be replaced NOTICE The inside space and nylon bush of the swing arm should be replaced together ...

Page 47: ...g deformation the wheel is to be replaced 2 Hub connected plate In case of scrape damage the hub connected plate is to be replaced 3 Bearing of hub connected plate In case of unsmooth operation of the connected plate or wheel as a result of the bearing the bearing is to be replaced 4 Oil seal In case of abrasion damage the oil seal is to be replaced Procedures for the replacement of hub connected ...

Page 48: ...It is enough that it reaches the center of the inner loop 5 Spindle In case of damage deformation the Spindle is to be replaced 6 Front shock absorber In case of spring deflection oil leakage and surface scrape the front shock absorber is to be replaced 7 Swing arm In case of damage deformation the swing arm is to be replaced Install Move back to the procedures of removal Note the following 1 Warn...

Page 49: ...bly 3 Rear Axle assembly 12 25 1 4 Sleeve Shaft Passenger 5 Sleeve Shaft Driver 6 Backing Plate Brake Driver 7 Backing Plate Brake Passenger 8 Brake Drum AC NKL 9 Hex Head Screw M10 1 25 35 10 Hex Head Screw M8 1 25 25 11 Serated Lock Nut M8 12 Brake Shoe kit 13 Brake cable clip ...

Page 50: ...ignated Lifting Jack 3 Wedge blocks onto the front lower part of the front wheels 4 Disconnect All the connecting lines of the electric motor 5 Remove Three bolts of the electric motor Electric motor Refer to Chapter 9 Removal of Motor 6 Put an oil tray under the differential gear unscrew the bleeding bolt to discharge all the lubricating oil in the differential case 7 Remove Wheel nut of rear whe...

Page 51: ... swing arm fixing nut Tightening torque 63N m 46 5ft 1b U bolt Driving axle 9 Remove Brake hub NOTICE In case the brake hub is difficult to remove knock out the hub with rubber hammer 10 Inspect Half axle operation Rotate the half axle connected plate with hand and in case of unsteady rotation or abrasion the half axle assembly is to be replaced 1 ...

Page 52: ...ncer pliers to separate the clipping spring and locating dowel of brake shoe 12 Remove Fixing bolt of half axle of rear axle Half axle assembly of rear axle Brake base plate NOTICE Knock out the half axle wheel rim of the rear axle lightly with a rubber hammer 13 Remove Fixing bolt of half axle outer tube Tightening torque 55N m 40 6 ft 1b Half axle outer tube ...

Page 53: ...ation the wheel is to be replaced NOTICE We do not recommend the replacement of bearing and bearing sleeve as an individual part During the operation the quality of fit between half shaft and bearing or bearing sleeve may deteriorate In this case we usually recommend the replacement of a new rear axle half shaft assembly In addition due to the complex internal structure of the brake we recommend t...

Page 54: ...rface of the bearing Basic grease 2 Install Brake base plate Half axle assembly of rear axle Bolt Nut Tightening torque 30N m 22 1 ft 1b 3 Install Half axle outer tube of rear axle Bolt Tightening torque 45N m 33 2 ft 1b 4 Install Brake shoe Upper tension spring Lower tension spring 11 Locating dowel Clipping spring 10 11 9 ...

Page 55: ...e shoe WARNING In handling the brake shoe ensure that the hands are clean and the shoe plate surface is not tainted with grease 5 Install Brake drum Rear wheel assembly Wheel nuts of rear wheel Tightening torque 90N m 66 4 ft 1b Bleeding bolt Tightening torque 70N m 51 7ft 1b Apply 800mL lubricating oil SAE80 to the rear axle 6 Install Oil filler screw plug ...

Page 56: ...Ball Bearing NO 6205 11 Shim Ø 61XØ 69X1 5t 12 Shim Ø 36XØ 44X1 5t 13 Shim Ø 32X Ø 40X1 0t 14 Shim Ø 45X Ø 51X1 5t 15 Washer Ø 8 2XØ 16X2 0t 16 Washer Ø 14 5XØ 22X1 0t 17 Seal Ø 28XØ 55X9h 18 Seal Ø 25XØ 47X6h 19 Bolt M8XP1 25X100L 20 Bolt M8XP1 25X90L 21 Bolt M8XP1 25X12L 22 Bolt M14XP1 5X9 5L 23 Nut M8XP1 25 24 Location Pin Ø8 2X Ø10X12L 25 Machine Key 26 Circlip shaft 32 27 Breather Tube 28 Rin...

Page 57: ...Driving Axle 6 9 Chapter 6 Removal of the Differential Gear 1 Remove 2 Remove Drain Screw Washer Bolt Nutx10set 2 Remove 3 Remove The gearbox Cover Remove 4 Remove Carrier Gear Assy Remove ...

Page 58: ...Driving Axle 6 10 Chapter 6 5 Disassemble 6 Remove 7 Remove Clip spring from countershaft gear Bearing Gear bush Countershaft Countershaft gear Shim Bearing Seal 08 Shim 07 Shim 09 Bearing 10 ...

Page 59: ...sion replacement is to be made Bearing In case of erosion damage replacement is to be made 8 Remove Location Pin 12 2 Install In the reverse order of the removal procedure and note the following 1 Install Gear box cover 2 Apply Oil Recommended oil Gear oil SAE 80 Oil volume 800mL Tightening torque 45N m 33 2 ft 1b ...

Page 60: ...er 4 Rear brake cylinder 7 Brake drum 9 Brake pedal base 10 Brake pedal ate 5 Front brake disc 6 Brake master sealant 11 Brake shoe pl 15 13 Return spring 14 Nut Locating dowel 16 Flat washer 20 Bolt 17 Split pin 18 Bolt 19 Nut 2 Oil hose 8 Iron oil tube 12 Bolt 21 Reservior 22 Clamp 23 Tee tube ...

Page 61: ...ve cover plate Refer to relevant content in Chapter 2 Brake pedal fixing bolt Brake pedal fixing nut Tightening torque 50N m 36 9 ft 1b Brake pedal Fixing bolt of brake master cylinder Fixing nut of brake master cylinder Tightening torque 45N m 33 2 ft 1b Brake master cylinder Brake pipe Tee tube Inspect Brake master cylinder Brake pipe Tee tube In case of oil leakage deformation damage replacemen...

Page 62: ... pedal 2 Accelerator 3 Accelerator bracket 4 Pivot 5 Split pin 6 Pin axle 7 Washer 8 Split pin 9 Flat washer 10 Lock washer 11 Throttle assy micro switch 12 Screw 13 Hall effect sensor Note Take off 4 screws of the cover you can see the Hall effet sensor in it ...

Page 63: ... 14 nut 15 universal joint spline 16 spline bearing of universal joint 17 dustproof cover of universal joint 18 nut 19 lock washer 20 flat washer 21 steering gear housing 22 nut 23 outer snap ring 24 tape 25 dustproof cover 26 adjusting nut 27 adjusting cap 28 stress spring 29 hold downs 30 oil seal 31 small gear bearing 32 inner snap ring 33 outer snap ring 34 dustproof cap 35 bearing 36 bushing ...

Page 64: ...ils 17 c o v e r 19 2 1 steering gear housing 22 nut 23 outer snap ring 24 tape 25 dustproof cover 26 adjusting nut 27 adjusting cap 28 stress spring 29 hold downs 30 oil seal 31 small gear bearing 32 inner snap ring 33 outer snap ring 34 dustproof cap 35 bearing 36 bushing 37 steering rod 38 gear 39 stopple washer 40 dustproof sleeve 41 ball joint 42 slotted nut 43 cotter pin 44 nut 45 tape 46 Re...

Page 65: ... wheel 5 Remove Dashboard Please refer to Chapter 4 Removal of the Dashboard Disconnect the connecting line of turn signal stalk Sleeve of turn signal stalk cable Bolt Turn signal stalk 6 Remove Upper fixing bolt of the block of steering column Tightening torque 20N m 14 8 ft 1b Lower fixing nut of the block of steering column 2 Assure that the E Brake switch is in the middle possition Normal Stee...

Page 66: ...e bearing on one side with the hydraulic press and extract the bearing with universal bearing extractor Extract the bearing on the other side in the same method The bearings once removed must be replaced with new ones Removal of the Steering Gear 1 Remove Split pin Slotted nut Tightening torque 25N m 18 4 ft 1b Universal joint assembly steering shaft end See chapter 8A for details Yoke bolt of low...

Page 67: ...int of the steering gear Secure the drawbar of the steering gear with one spanner and loosen the locknut with another spanner Tape NOTICE The tape once removed will be a destroyed and should be replaced with a new one 2 Disassemble Dust boot of steering gear 3 Disassemble Thrust washer Drawbar of steering gear Fixing bolts on the steering gear ...

Page 68: ... be fixed in the skewed slot 4 Disassemble Locknut Adjusting cover Spring Pressing block NOTICE Seize and pull out the pressing block with nipper pliers which can make the disassembly easier 5 Disassemble Oil seal Inner clasp Outer clasp Pinion shaft NOTICE The oil seal once removed must be replaced with new one Turn the pinion shaft with hand to inspect the operation of the bearing In case of uns...

Page 69: ...replacement of worn parts in the steering gear individually To ensure sound operating performance we usually recommend the replacement of a new steering gear assembly Whether the operation of rack is smooth NOTICE Improper adjustment or lack of lubrication of the gear teeth may result in irregular abrasion Whether the dust boot has ruptures or scrapes ...

Page 70: ...ly a thin layer of grease Install In the reverse order of the removal procedures Refer to the schematic diagram of system parts Adjust the tightening torque of the cover 1 5 2 N m 1 1ft 1b 1 48ft 1b NOTICE The steering gear should have no clamping stagnation when the left and right racks turn to the final positions When they return to the middle position the free gap of the steering wheel should b...

Page 71: ...tor EPS 2 Compound steering joint UPPER 3 Bolt Hex Head M8 30 4 Lock washer 8mm 5 Flat washer 8mm 6 Bolt Hex Head Flange M8 20 7 Holder EPS 8 Compound steering joint LOWER 9 ECU EPS 10 Bolt hex head flange M10 60 1 25 11 Wire harness EPS 12 Screw hex head M6 12 13 Flat washer 10mm 14 Self locking nut M10 1 25 ...

Page 72: ...System 8A 2 Removal of ECU Electrical Control Unit 1 Loosen the cable ties 2 Remove the assorted screws 3 Remove Motor Torque Sensor wire to ECU end plug 3 Remove DC convetor wire to ECU front plug Remove Motor wire to ECU other front plug ...

Page 73: ...ing shaft end 2 Remove Motor Holder bracket to chassis with two M10 60 Flange Bolts 1 With 13mm open end wrench remove yoke bolt of upper steering shaft end 3 With 13mm open end wrench remove yoke bolt of lower steering shaft end 4 Removed the steering gear box assembly to chassis with three M10 35 Flange Bolts And then can take out of EPS Assy ...

Page 74: ...olt and then remove the Compound steering joint LOWER Install In the reverse order of the removal procedure and note the following 1 Yoke bolts Compound steering joint tightening torque 25N m 18 4 ft 1b 2 Three bolt3 EPS holder tightening torque 35N m 25 ft 1b 3 Two bolt3 EPS holder to chasss tightening torque 45N m 33 2 ft 1b 4 Three bolt3 steering gear box assembly to chassis to chasss tightenin...

Page 75: ...Chapter 8A Electrical Power Steering System Electric Schenatic Diagram Include EPS System 8A 5 ...

Page 76: ... the key switch until the plug in package connecting the key switch wire to the main cable appears disengage the plug in package of the key switch wire from that of the main cable 5 Hold the key switch and remove the switch lock nut from outboard of instrument panel 6 Check Refer to Check Procedure 6 Circuit check for key switch and accelerator pedal switch of Chapter 10 replace the part in case o...

Page 77: ...tions Installation of forward reverse switch Back to the removal steps NOTE The blue white black black yellow wires must be connected correctly at relevant positions on the gear switch Removal of headlight power switch Please refer to Chapter 1 Protection for Electrical Safety 2 Take out the key from the key switch 3 Remove the middle electrical regaining plate 1 Assure that the E Brake switch is ...

Page 78: ...ectrical regaining plate 1 Assure that the E brake switch is in the middle possition Normal 4 Remove the connecting wire from emergency switch 5 Press the snap locks on the upper and lower ends of the switch push switch out of the housing Removal of Battery power level indicator Please refer to Chapter 1 Protection for Electrical Safety 2 Take out the key from the key switch 3 Remove the middle el...

Page 79: ... disengage the plug in package of the key switch wire from that of the main cable 6 Check Refer to Check Procedure 6 Circuit check for key switch and accelerator pedal switch of Chapter 10 replace the part in case of any inconsistency Key switch installation Back to the removal steps 1 2 3 4 5 1 Assure that the E Brake switch is in the middle possition Normal 1 2 3 Remove the steering wheel and st...

Page 80: ... The blue white black and blcak yellow wires must be connected correctly at relevant positions on the gear switch 1 Assure that the E brake switch is in the middle possition Normal Removal of high low speed switch Please refer to Chapter 1 Protection for Electrical Safety 2 Take out the key from the key switch 3 Remove the steering wheel 4 Remove the steering stem cover 6 Check Continuity of the h...

Page 81: ...dle el ectrical regaining plate 1 Assure that the E Brake switch is in the middle possition Normal 4 Remove the connecting wire from emergency switch 5 Press the snap locks on the upper and lower ends of the switch push switch out of the housing Removal of Battery power level Please refer to Chapter 1 Protection for Electrical Safety 2 Take out the key from the key switch 3 Remove the middle elect...

Page 82: ...onnected correctly at relevant positions on the battery discharge meter Horn removal 1 Take out the key from the key switch Please refer to Chapter 1 Protection for Electrical Safety 3 Disconnect the horn wire 4 Remove the horn bolt and remove the horn 5 Check the horn for continuity Replace the part in case of un continuity Assure that the E Brake switch is in the middle possition Normal 2 Assure...

Page 83: ...from the key switch Please refer to Chapter 1 Protection for Electrical Safety 3 Remove the protective sleeve for the wire harnesses of combination switch 4 Remove the bolts 2 from the top of the switch 5 Remove the instrument panel refer to the relevant contents in Chapter 4 6 Disconnect the wire plug in package of the combination switch and remove the combination switch 2 Assure that the E Brake...

Page 84: ...f the switch 6 Disconnect the wire plug in package of the combination switch and remove the combination switch 2 Assure that the E brake switch is in the middle possition Normal Please refer to Chapter 1 Protection for Electrical Safety 2 Take out the key from the key switch 3 Remove the steering wheel 4 Remove the steering stem covers 1 Assure that the E brake switch is in the middle possition No...

Page 85: ...l 1 Take out the key from the key switch 3 Remove the trunk lid 4 Remove the rear plate plastic screw 5 Remove the rear plate 6 Remove the safety belt buckle set bolt Tightening torque 20N m 14 7ft 1b 7 Remove the safety belt buckle 8 Disconnect all wires and multi wire connectors from the controller Please refer to Chapter 1 Protection for Electrical Safety 2 Assure that the E Brake switch is in ...

Page 86: ...SE 9 7 1 E brake ...

Page 87: ...egulator connector Lb R R B L W B Y B B P B W Y R W turn switch G Y Br Lg horn switch B B W B L B Lg R H L beam switch R L Pu R warning switch Y B R W Y B Y L Wiper W L Br W G W Y R Y W Speedometer Y R Y W W L Br W G W Lb Br Y B Lb R W G R W R B R Br G Y O B 1N5402 1N5402 H L speed switch Charge control signal 1N5402 W W Ⅰ Ⅱ E brake switch Br L Y R B R B B Power display Lb Y L inner top light swit...

Page 88: ...peration When Forward Reverse switch is on FORWARD position make sure the electric vehicle is running forward When Forward Reverse switch is on REVERSE position make sure the electric vehicle is running backward When Forward Reverse switch is on REVERSE position the reverse buzzer should sound a warning tone When Forward Reverse switch is on NEUTRAL position make sure the electric vehicle remains ...

Page 89: ...ff the 4 screws fixing the charger receptacle plate to the socket bottom and the car body 6 Remove the charger receptacle retaining plate and charger receptacle 7 Check Check the receptacle for cracks poor contact and wear and replace the part if necessary Charger receptacle installation Back to the removal steps Battery removal 1 Take out the key from the key switch 3 Remove the seat pad assembly...

Page 90: ...he battery add distilled water to 13mm above the plate electrode if the level is below the plate electrode Battery installation Back to the removal steps NOTE The battery must be removed with a special battery lifting tool DC converter removal 1 Take out the key from the key switch 3 Remove the rear seat pad assembly Please refer to Chapter 1 Protection for Electrical Safety 4 Disconnect the wire ...

Page 91: ...Electric Component 9 11 Chapter 9 6 Remove the DC converter DC converter installation Back to the removal steps ...

Page 92: ...rom the connecting terminal of the motor 4 Remove the 3 bolts which fixing the motor 2 Assure that the E Brake switch is in the middle possition Normal 5 Wrap the motor at the mid position with a wide band lift the motor carefully and move it to the left horizontally then place it on the ground gently NOTE The motor is heavy lift and place with care ...

Page 93: ...cal Safety 2 Unplug the 4 wire connector from the hardness of the electric vehicle 3 Unplug the temperature and E brake connector from the hardness of the electric vehicle 4 Take down the speed sensor of the motor from the end shield of the electric motor with a screwdriver Mounting of the speed sensor of electricmotor 1 Mount the speed sensor 2 Plug the speed 4 wire connector and E brake connecto...

Page 94: ...t with a Philips driver 5 Remove the headlight pull apart the power cord from the headlight bulb 6 Remove the 2 screws fixing the bulb with a screw driver and take out the headlight bulb 7 Turn the lamp receptacle of the front turn signal light and remove the turn signal lamp bulb 8 Check the bulbs of the headlight and the turn signal lamp for continuity and replace the part in case of un continui...

Page 95: ...he 4 snaps on the lens the tail light must be replaced if any of them is broken 4 Disconnect the wire Tail light installation Back to removal steps High mount stop lamp removal 1 Take out the key from the key switch 2 Turn E brake switch to middle position Please refer to Chapter 1 Protection for Electrical Safety 3 Remove the screws with a screwdriver 2 Assure that the E Brake switch is in the mi...

Page 96: ...ce the bulb assembly with wire harness in case of un continuity High mount stop lamp installation Back to removal steps Wiper removal 1 Take out the key from the key switch Please refer to Chapter 1 Protection for Electrical Safety 3 Disconnect the wiper 4 Remove the wiper arm 5 Remove the fixing nut of wiper motor 2 Assure that the E Brake switch is in the middle possition Normal ...

Page 97: ...of inner mirror 2 Fix the bracket on windshield frame 3 Take off white lense 4 Fix the mirror on the bracket 2 Assure that the E Brake switch is in the middle possition Normal 5 Cover the light with white lense 6 fix the wire clip on the windshield frame along left side of it 7 connect the connector connect one side of the two output of connector of inner mirror with wire the other side with the o...

Page 98: ...ntact and broken wire Refer to Check Procedure 7 Controller signal High pedal check Drive in correct way Motor failure Chapter 12 Motor Controller failure Replace controller Refer to Controller removal in Chapter 9 The electric vehicle can t be started Speed sensor disconnection or failure Page 10 Check Procedure 9 Motor speed sensor Wrong speed setting The set max speed of the electric vehicle ca...

Page 99: ...e battery charger can t charge the battery Battery charger Refer to relevant maintenance and repair instructions for battery charger DC converter failure Replace DC converter Lighting fuse blowing out Replace fuse Auxiliary contactor failure Replace contactor Bulb damaged Replace bulb Headlight failure Combination switch failure Replace combination switch DC converter failure Replace DC converter ...

Page 100: ...ly Wires and harnesses not arranged and fixed correctly can result in electric vehicle failure property damage and casualties Index for check procedures 1 Battery voltage check 2 Accelerator signal voltage 3 Motor voltage at U V W 4 E brake switch 5 Battery voltage under voltage 6 Circuit of key switch and accelerator pedal switch 7 Controller signal 8 Motor speed sensor 9 Forward reverse gear swi...

Page 101: ... the reading is lower than 4 5V when the pedal is pressed down completely the electric vehicle can not run at the rated max speed Please check whether the accelerator is in good condition Check Procedure 3 Motor voltage at U V W Please refer to Chapter 1 Protection for Electrical Safety 1 Jack up the rear axle of the vehicl so that the rear wheels are in the air 2 Check that the battery is wired c...

Page 102: ...ed battery in good condition the reading should be lower than 41 at under voltage 4 A reading of 41V indicates a discharged or faulty battery Each battery should be checked in under voltage state with a multimeter 5 Don t start the discharger if the voltage is lower than 41V If the battery voltage is lower than 41V it indicates the battery is completely discharged or faulty 6 Record the voltage re...

Page 103: ...er set at 200V DC connect the black probe to the negative binding post of Battery No 8 and connect the red probeto the pedal switch output connector wire 2 Wire Green 9 2 When the E brake switch is on Normal position the key switchis ON and Forward Reverse switch is on NEUTRAL the voltage reading should be 24V When the accelerator pedal is depressed the voltage reading should be reference voltage ...

Page 104: ...tage When at high speed input 0V voltage Pin 11 yellow wire Output signal to speedometer When the motor running output rotation signal to speedometer Pin 13 red white wire CAN bus High signal When controller working properly output 5V voltage Pin 14 black red wire Digital pulse from speed encoder A When motor running speed encoder A output signal to this pin Pin 15 brown wire Encoder power supply ...

Page 105: ... signal Pin 25 Green Yellow wire Digital pulse from speed encoder B When motor running speed encoder B output signal to this pin Pin 26 White red wire Encoder power supply When controller working properly output 5V Pin 28 Brown Yellow wire CAN power supply when the controller working properly provides 24V voltage to the accelerator Pin 30 Blue white wire Digital input Reverse input signal provided...

Page 106: ...wire the multimeter should show connecting status Check Procedure 7C Pin 3 and 4 1 Use a multimeter set at 200V DC connect the red probe onto the Contactor coil post 1 Refer to the following Note Connect the black probe to the Contactor coil post 2 Δ Note Never insert the complete probe into the 35 wire plug for fear of poor contact 2 When the key is on the multimeter should display a 48V DC volta...

Page 107: ...ay a full Δ Note Never insert the complete probe into the 35 wire plug for fear of poor contact 2 When the High Low switch is turned on Low multimeter should display a 24V DC voltage Continuity of wires in harness If the High Low speed switch working properly 3 When the High Low switch is turned on High multimeter should display a 0V DC voltage 4 If another reading is displayed the following items...

Page 108: ...ding post of the battery pack and connect the red probe to the terminal 2 or 3 of the 4 wire connector on the motor speed sensor The voltage reading should be approximately 0 5V 5 2 If the reading is incorrect check the continuity between terminal 2 or 3 of 4 wire connector and controller If the continuity is ok replace the speed sensor connect t If you want run the motor Jack up the rear axle of ...

Page 109: ...ndicated If the reading is not correct replace the switch 3 Connect the black probe to Position 1 or 2 of the switch then connect the red probe to Position 3 or 4 When the switch is on NEUTRAL or FORWARD no continuity should be indicated When the switch is on REVERSE continuity should be indicated If the reading is not correct replace the switch Check Procedure 10 Reverse buzzer 1 Disconnect the b...

Page 110: ...connector 13 In case of un continuity of the blue white wire or improperly plugged Pin 30 of the controller repair or replace the part as required Check Procedure 11 Battery discharge meter Please refer to Chapter 1 Protection for Electrical Safety The main cable has three wires connected to the battery discharge meter red wire connected to 10A fuse light blue wire connected to key switch and blac...

Page 111: ...asured voltage is still 0V replace the main cable Check Procedure 13 wiper Please refer to Chapter 1 Protection for Electrical Safety Turn the key switch to ON check the wire connected to the wiper of main cable with a multimeter set at 200V DC connect the red probe to yellow blue wire and connect the black probe to black wire The voltage should be 12V Perform the following checks if the voltage i...

Page 112: ... LED in a pattern determined by the fault type and severity 4 Logs the fault for later retrieval Fault identification You can identify a fault as follows Check the number of LED flashes and use below to determine what action can be taken A complete and comprehensive fault identification table will be available from Sevcon in due course Pick up the EMCY on the CANbus and read the fault condition us...

Page 113: ...e Release handbrake 2 Sequence fault DI Any drive switch active at power up Reset drive switches 2 SRO fault DI FS1 active for user configurable delay without a direction selected Deselect FS1 and select drive 2 FS1 recycle DI FS1 active after a direction change Reset FS1 2 Seat fault DI Valid direction selected with operator not seated or operator is not seated for a user configurable time in dri...

Page 114: ...cuit driver VS Analog output fault caused by over current 4A under current if actual current 50 target current mode only failsafe circuit fault short circuit driver MOSFET Check analog output wiring 7 BDI warning or cutout I BDI remaining charge is less than warning or cutout levels Charge battery 7 Battery low voltage protection I Battery voltage or capacitor voltage is below a user definable min...

Page 115: ...temperature Remove loading to allow controller to cool down 8 Controller too cold I Controller has reduced power to motor s below maximum specified by user settings due to controller under temperature Allow controller to warm up to normal operating temperature 8 Motor over temperature I Controller has reduced power to motor s below maximum specified by user settings due to motor over temperature R...

Page 116: ...eter error RTB Motor parameter written to while motor control is operational Recycle keyswitch to allow parameters to be reloaded correctly 14 3rd Party Anonymous Node EMCY received I DS RTB 3rd party node has transmitted an EMCY message Check CANbus wiring and 3rd party node status 15 Vehicle service required I Vehicle service interval has expired Service vehicle and reset service hours Table 8 F...

Page 117: ...tition is verifiably an element that separates the positive plate and negative plate and prevents their contact Their contact will result in the short circuit The partition has sufficient holes to allow the passage of charged ions through positive and negative plates while preventing the contact of the plates Two different metals that are immersed into one acid can generate the electric current In...

Page 118: ...ommon misconceptions about battery Common misconceptions about the deep cycle battery of electric vehicle and the maintenance of the battery are shown in the table below Problems Misconceptions Actual states Deep discharge The electric vehicle runs slowly but we still can have it run until it has no electrical energy Try to avoid the deep discharge of battery Please refer to deep discharge Prematu...

Page 119: ...ols To prevent the electrolyte from leaking out of the battery air bleeders the battery must remain upright Inclination of over 45 towards any direction may result in the leakage of small amount of electrolyte from the air bleeder The inclination of the battery should not exceed 45 when being lifted carried or mounted The battery acid may result in serious personal injury to the skin or eyes and m...

Page 120: ...lb 12 4N m torque Apply terminal protection oil to all connecting terminals to minimize the potential corrosion 7 Fully charge the battery before use In this way the battery can be ensured to have been fully charged before use and the electric quantity of the battery compartment is balanced Battery maintenance Preventative maintenance To maintain the battery in good working order please take the f...

Page 121: ...hould remain clean all the time The temperature also has influences on the speed of self discharge by the battery The higher the temperature is the quicker a set of battery is discharged In hot regions the battery should be inspected more frequently The battery should be stored in shady and cool places Please refer to storage of battery Electrolyte liquid level Δ NOTICE The battery acid exuded fro...

Page 122: ... water must be ensured to contain minerals of which the contents are below the level specified below Impurities Allowable content ppm Suspended substance Cannot be viewed visibly Total solid 100 0 Calcium and magnesium oxides 40 0 Iron 5 0 Ammonia 8 0 Organic matter 50 0 Nitrate 10 0 Nitrite 5 0 Chloride 5 0 Vibration damage The battery hold down gear should remain tight and secure to prevent the ...

Page 123: ...remarkably and may result in the irremediable defect of the battery In case the battery is fully discharged it may be unable to be charged any longer To more the battery is discharged the harder the battery is able to bear Therefore it is suggested that every time the battery is used in case the charging cycle is not interrupted and the charger can shut off automatically the electric vehicle is ch...

Page 124: ...teries Electric vehicle and charger numbering If possible the electric vehicle is desirable to be charged by one and the same charger every night In case the electric vehicles are stored in the garage at random and one of the vehicles breaks down during operation and the inspection shows that the battery is normal the cause may very likely be the abnormality of the charger However it is time consu...

Page 125: ...adings doesn t exceed 0 7V In case the reading of any single battery is lower than 7V and its difference with the battery that has a voltage of over 7V exceeds 0 7V the battery should be replaced All the readings are higher than 5 3V but the difference of any two readings doesn t exceed 0 7V It may be used battery Carry out hydrometer test Hydrometer test Replace the battery that the specific grav...

Page 126: ...tart the charger Five minutes later measure and record the voltage of the battery pack and of each battery with the multimeter Set the multimeter at 200V DC Attach the red probe to the positive terminal of No 1 battery and attach the black probe to the negative terminal of the battery pack see Fig 11 5 Take down the reading Then set the multimeter at 20V DC Attach the red probe to the positive ter...

Page 127: ...same as the eyes and observe the scale value of the liquid level of electrolyte see Fig 11 8 6 Take down the reading and enable the electrolyte in the hydrometer to return back to the battery compartment Replace the air bleeder cover 7 Repeat Step 2 6 to all battery compartments Calibration of hydrometer Most of the hydrometers are calibrated and can perform precise measurement under 80 26 7 The a...

Page 128: ...48 1 200 012 1 188 1 270 012 1 258 1 270 012 1 258 Defective battery 2 69 5 80 F 26 7 C 000 1 250 0 1 250 1 255 0 1 255 1 230 0 1 230 1 250 0 1 250 Light current battery 3 additional charge 38 2 100 F 37 8 C 008 1 200 008 1 208 1 180 008 1 188 1 170 008 1 178 1 180 008 1 188 Discharged battery recharge and re inspection 22 4 80 F 26 7 C 000 1 240 0 1 240 1 245 0 1 245 Buoy doesn t float 1 250 0 1 ...

Page 129: ...er and restart the tester 5 Sixty minutes after the discharge of the battery set the discharger at function 3 and measure the voltage of the battery pack In the subsequent test measure the voltage every ten minutes Measure with the multimeter the voltages of all batteries when the voltage of the battery pack is higher than the shutoff point 42 0V by 5V Be accurate to 0 01V and measure and take dow...

Page 130: ...esults are recorded As battery No 3 No 1 and No 4 are suspected to have problems hydrometer inspections are conducted on all batteries Electrolyte temperature Discharge time when the shut off point is reached Electrolyte temperature Discharge time when the shut off point is reached 40 49 4 9 40 minutes 85 89 29 32 64 minutes 50 59 10 15 45 minutes 89 99 32 37 66 minutes 60 64 16 18 50 minutes 100 ...

Page 131: ...tore the battery in shady and cool places The lower the temperature where the battery is stored is the less electricity quantity the battery self discharges The electric quantity discharged by the battery stored in 0 17 8 temperature is very little The battery stored under 80 26 7 temperature will discharge every few weeks 5 The 48V E merge electric vehicle that is not to be used for a long time i...

Page 132: ... it will conclude that the storage battery is fully charged and will shut off the charger Conditions to be noted before charging WARNING Electric shock hazard The vehicle is provided with the on board charger Before the operation of the charger the vehicle must be driven to and stopped at a platform higher than the ground in such a way to allow the maximum draught blow and surrounding the charger ...

Page 133: ... will damage the DC connector WARNING Ungrounded electric installation will be a material hazard for electric shock or electrocution The charging dc wire is provided with a polarization connector that can be plugged into the on board electrical outlet Power supply AC wire is provided with a grounded connector Never unplug cut off or bend the ground pole NOTICE In case the vehicle is to be charged ...

Page 134: ... damage to the equipment or the charger before the repair or maintenance procedures please see to it to unplug the charger from the AC and DC power supply Removal of the charger WARNING When the charger is still connected with the power supply it has lethal voltage when the cover is removed If you suspect your ability to safely perform the following tests you can ask the trained electrician techni...

Page 135: ...ISOLÉES DE L ACCUMULATEUR 9 CAUTION CHARGE ONLY BATTERIES OF THE SAME TYPE VOLTAGE CELL NUMBER AND AMP HOUR CAPACITIES AS SHOWN ON THE LABEL OTHER TYPES OF BATTERIES MAY BURST CAUSING PERSONAL INJURY AND DAMAGE BEFORE CHARGING ANY OTHER TYPE OF RECHARGEABLE BATTERY CHANGE THE CHARGER SETTINGS AS RECOMMENDED BY THAT BATTERY MANUFACTURER 10 ATTENTION UTILISER POUR CHARGER UNIQUEMENT LES ACCUMULATEUR...

Page 136: ...Description Slow Blink Off Bulk Start charge cycle phase constant power or constant current Fast Blink Off Absorption Plateau charge cycle phase constant voltage Greater than 80 charged Solid On Off Finish charge cycle phase constant current Not all charge profiles include a Finish phase Off Fast Blink Balance Equalize phase An extended charge cycle is occurring because a trigger condition has bee...

Page 137: ...low Blink 0 0 NO AC AC power was lost during charging Charge cycle will restart when AC power returns Slow Blink 1 Slow Blink HARDWARE FAULT Contact Lester Electrical Slow Blink Slow Blink 0 HARDWARE FAULT Contact Lester Electrical Slow Blink Slow Blink 1 HARDWARE FAULT Contact Lester Electrical Fast Blink N A N A HARDWARE FAULT Contact Lester Electrical Unit is still able to charge Battery 1 0 0 ...

Page 138: ...ge cycle b The charger DC output connector was disconnected from the battery during the charge cycle c The battery has been allowed to sulfate Charge the battery at least once every three 3 days when the equipment is lightly used Once sulfation is allowed to take place it may be partially reduced by returning temporarily to daily charging 3 A decrease in vehicle equipment range where the battery l...

Page 139: ...ug from the battery while a charge cycle is in progress 5 The charge cycle 80 point is indicated by the Charge Status yellow LED beginning to blink quickly 6 The Finish charge cycle phase is indicated by the solid illumination of the Charge Status yellow LED Not all charge profiles include a Finish phase 7 An extended Balance Equalize charge cycle phase is indicated by the Charge Complete green LE...

Page 140: ...CHARGER PENDANT QUE L EQUIPMENT EST EN MARCHE WARNING LEAD ACID BATTERIES GENERATE GASES WHICH CAN BE EXPLOSIVE TO PREVENT ARCING OR BURNING NEAR BATTERIES DO NOT DISCONNECT THE CHARGER DC OUTPUT FROM THE BATTERIES WHEN THE CHARGER IS OPERATING KEEP SPARKS FLAME AND SMOKING MATERIALS AWAY FROM BATTERIES WARNING ALWAYS SHIELD EYES WHEN WORKING NEAR BATTERIES DO NOT PUT WRENCHES OR OTHER METAL OBJEC...

Page 141: ...1115 Commercial Avenue Reedsburg WI 53959 Phone 608 524 8888 Fax 608 524 8380 800 222 4653 Web www columbiavehicles com ...

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