Hisun HS5DUTV-2, Maintenance Handbook

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MAINTENANCE AND ADJUSTMENT OF THE EV
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If the problem cannot be solved. Stop and evaluate all conditions prior to the
problem. If the EV must be taken to a repair facility, the mechanic will want to know as
many details as possible.
For removal, installation and test procedures for some components, refer to the
specific chapter. When applicable, tables at the end of each chapter also provide
specifications and service limits.
ELECTRICAL TESTING
This section describes basic electrical testing and test equipment use.
Preliminary Checks and Precautions
Refer to the color wiring diagrams at the end of the manual for component and
connector identification; Use the wiring diagrams to determine how the circuit should
work by tracing the current paths from the power source through the circuit
components to ground. Also, check any circuits that share the same fuse (if used),
ground or switch. If the other circuits work properly and the shared wiring is good, the
cause must be in the wiring used only by the suspect circuit. If all related circuits are
faulty at the same time, the probable cause is a poor ground connection or a blown
fuse (if used).
As with all troubleshooting procedures, analyze typical symptoms in a systematic
manner. Never assume any thing and do not overlook the obvious like a blown fuse or
an electrical connector that has separated. Test the simplest and most obvious items
first and try to make tests at easily accessible points on the EV.
Before starting any electrical troubleshooting, perform the following:
1. Check the fuse if the fuse is blown, replace it.
2. Inspect the battery. Make sure it is fully charged, and the battery leads are clean and
securely attached to the battery terminals.
3. Disconnect each electrical connector in the suspect circuit and make sure there are
no bent terminals in the electrical connector
4. Make sure the terminals on the end of each wire are pushed all the way into the
connector. If not. Carefully push them in with a narrow blade screwdriver
5. Check the wires where they connect to the terminals for damage
6. Make sure all terminals within the connector are clean and free of corrosion. Clean
them. If necessary. And pack the connectors with dielectric grease
7. Push the connectors with dielectric grease. The connectors are fully engaged and
locked together
8. Never pull the electrical wires when disconnecting an electrical connector-pull only
on the connector
Intermittent Problems
Intermittent problems are problems that do not occur all the time and can be difficult
to locate. For example. When a problem only occurs when the EV is ridden over rough
roads (vibration) or in wet conditions (water penetration). It is intermit-ten. To locate
and repair intermittent problems. Simulate the condition when testing the compo-nets.
Note the following:
1. Vibration---This is a common problem with loose or damaged electrical connectors