Oldenbourg group euv-400 Parts And Service Manual Download Page 1

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EUV-400 ELECTRIC UTILITY VEHICLE

PARTS AND SERVICE MANUAL

PUB. NO. 1486

OLDENBURG ELECTRIC UTILITY VEHICLE INCLUDES:



25 HP OLDENBURG ELECTRIC AC MOTOR



HEAVY DUTY DANA 44 DRIVE AXLES



FRONT AND REAR DISC BRAKES



ATLAS TRANSFER CASE



FLUX VECTOR VARIABLE SPEED AC DRIVE



DIGITAL GRAPHIC DISPLAY



REMOVABLE BATTERY PACK WITH QUICK DISCONNECT

with AMP Electric Drive

Revision

November

2010

Summary of Contents for euv-400

Page 1: ...URG ELECTRIC UTILITY VEHICLE INCLUDES 25 HP OLDENBURG ELECTRIC AC MOTOR HEAVY DUTY DANA 44 DRIVE AXLES FRONT AND REAR DISC BRAKES ATLAS TRANSFER CASE FLUX VECTOR VARIABLE SPEED AC DRIVE DIGITAL GRAPHIC DISPLAY REMOVABLE BATTERY PACK WITH QUICK DISCONNECT with AMP Electric Drive Revision 2 November 2010 ...

Page 2: ......

Page 3: ...ions 2 4 Battery Safety 2 8 3 PARTS Introduction 3 2 Electric Utility Vehicle EUV 3 5 Electrical Group 3 7 Motor Group 3 12 Battery Group 3 13 Wheel Group 3 14 Drop Box Group 3 15 Axle Suspension Group 3 16 Steering Group 3 19 Driveline Group 3 20 Brake Group 3 21 Options 3 23 4 SERVICE Cleaning 4 2 Storage 4 2 General Service 4 3 Service Intervals 4 7 Service Lubrication 4 8 Recommended Fluids 4 ...

Page 4: ...F and are included on the CD provided with your manual COMPONENT DOCUMENT S SOURCE Oldenburg AC Electric Motor How To Get The Most From Electric Motors EASA Atlas Transfer Case Specifications and Instructions Guide Advance Adapters Inc Dana Drive Axles Illustrated Parts Lists and Service Manual Dana Roadranger Sevcon Motor Controller Applications Reference Manual Sevcon SKF Sensor Bearing Unit Pro...

Page 5: ...alified personnel and must never service the machine unsupervised Information in this manual must be reviewed and understood before using this machine Failure to comply could result in serious injury or damage to the machine The manufacturer accepts no liability for damage or injury resulting from machine misuse and these risks must be borne solely by the user Compliance with and strict adherence ...

Page 6: ...n off highway application driveline including Dana drive axles and an Atlas transfer case The machine has a front and rear disc hydraulic service brake system cab operated parking brake and emergency driveline brake The machine has a 500 lb payload capacity and spare battery pack REQUIRED WORKING SPACE Machine turn radius of 4 68 meters 184 inches ...

Page 7: ... can build up on surfaces causing an unsafe condition It is also important to keep the machine clean for proper operation of the moving components and for serviceability of the machine Length 144 inches Width 63 inches Height 81 5 inches Weight pounds 4 320 Electric Motor Oldenburg 25 HP AC 30 min rating Outside Turning Radius 16 8 1 3 3 Payload pounds 500 lbs Maximum Speed 6 5 mph Maximum Gradien...

Page 8: ...NT MANUFACTURER PART OR MODEL NUMBER SERIAL NUMBER AC MOTOR OLDENBURG FRONT AXLE DANA REAR AXLE DANA TRANSFER CASE ADVANCE ADAPTERS PLEASE HAVE UNIT AND COMPONENT SERIAL NUMBERS WHEN ORDERING For proper notification of all updates and bulletins please complete Original Equipment Manufacturer product registration for all applicable machine components A component data plate is attached to major mach...

Page 9: ...lified personnel and must never service the machine unsupervised Information in this manual must be reviewed and understood before using this machine Failure to comply could result in serious injury or damage to the machine In addition to all safety measures outlined in this manual personnel shall adhere to all applicable workplace practices and regulations To maintain optimum performance from thi...

Page 10: ...are some of the safety alerts labeled on your machine When you see these you must be alert to the potential for personal injury if instructions are not followed properly The following labels are critical to the safety of personnel operating or servicing the machine Review these and fully understand these prior to operating the machine or performing any service on the machine Brake Test Park Brake ...

Page 11: ...2 3 SECTION 2 SAFETY Seat Belts Battery Disconnect Battery Disconnect ...

Page 12: ...amaged safety signs Keep your machine in proper working condition Unauthorized modifications to the machine may impair the function and safety and affect machine service life WEAR PROTECTIVE CLOTHING AND PROTECTIVE DEVICES Wear close fitting clothing and safety equipment appropriate to the job This may include but not be limited to the following items Eyewear gloves hardhat steel toe boots and hea...

Page 13: ...air behind your head Do not wear a neck tie scarf necklace or loose fitting clothing when working around operating machine These items can get caught and pull you into moving parts resulting in severe injury or death Stop engine and be sure driveline is stopped before performing maintenance PRACTICE SAFE MAINTENANCE Understand service procedure before doing work Read appropriate technical manual f...

Page 14: ...otentially harmful waste can include such items as oil brake fluid hydraulic fluid and batteries Use leak proof containers when draining fluids Do not use beverage containers that may mislead someone into drinking from them Do not pour waste onto the ground down the drain or into any water source Air conditioning refrigerants escaping into the air can damage the Earth s atmosphere Recover and recy...

Page 15: ...on Welding can structurally weaken or deform the wheel When inflating tires use a clip on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly Check tires for low pressure cuts bubbles damaged rims or missing lug bolts and nuts RIDERS CAN FALL OFF AND BE KILLED Seating is provided for operator and one passenger No riders are allowed i...

Page 16: ...tery The Absorbed Glass Matt construction allows the electrolyte to be suspended in close proximity with the plates active material In theory this enhances both the discharge and recharge efficiency Common manufacturer applications include high performance engine starting power sports deep cycle solar and storage battery The larger AGM batteries we sell are typically good deep cycle batteries and ...

Page 17: ...2 9 SECTION 2 SAFETY Follow safety Warning labeled on battery disconnect door Follow safety Warning labeled on battery pack ...

Page 18: ...apable of delivering high currents if the external terminals are short circuited The resulting heat can cause severe burns and is a potential fire hazard Accidentally placing metal objects across the terminals can result in severe skin burns It is a good practice to remove all metallic items such as watches bracelets and rings when installing or servicing batteries As a further precaution insulati...

Page 19: ...udes illustrated parts breakdowns starting with the overall machine and including all major parts groups and components This section does not include common hardware or wiring rather it is focused on providing parts information for maintenance significant parts which are those items likely to be stocked as spare parts or are more likely to be replaced during repair Read and understand manual and s...

Page 20: ...NTRODUCTION This section provides an illustrated parts breakdown of maintenance significant service parts The first illustration is that of the Electric Utility Vehicle which identifies each major group of parts Major Parts Group ...

Page 21: ...groups are then illustrated and maintenance significant service parts are identified Each illustration provides a view of where it is located on the machine locator view and identification of each part Locator View Parts Identification ...

Page 22: ...nformation that describes the part When using the electronic version of this document blue text indicates a hyperlink to allow for easy navigation Click on the parts group to go to the breakdown of that parts group Click on the browser back button to go back to the overall machine view Part Name Part Information Part Number Quantity Go to parts group ...

Page 23: ...CTION 3 PARTS ELECTRIC UTILITY VEHICLE EUV 400 Motor Group Steering Group Axle Suspension Group Wheel Group Electrical Group Frame 705769 Hood Latch 400674 Qty 1 Vinyl Seat 106167 Qty 2 Seat Belt 007369 Qty 2 ...

Page 24: ... ELECTRIC UTILITY VEHICLE EUV 400 Wheel Group Axle Suspension Group Drop Box Group Frame 705769 Electrical Group Driveline Group Brake Group Battery Group Options Fire Extinguisher 401354 Qty 1 Steering Wheel 706105 Qty 1 ...

Page 25: ...RTS ELECTRICAL GROUP Toggle Switch 0602129 0053 Qty 1 Toggle Switch 400396 Qty 1 Heavy Duty Toggle Switch 007958 Qty 1 Clear View Display Unit 706062 Qty 1 Pushbutton Switch 007499 Qty 1 Pushbutton Switch 007499 Qty 1 ...

Page 26: ...onnect Switch 705885 Qty 1 72 VDC to 24 VDC 300 Watt Converter 705962 Qty 1 Gen 4 PMAC Motor Controller 705727 Qty 1 24V 300 A Line Contactor 705728 Qty 1 Sight Glass to monitor Controller LED Status Light Cover Removed Battery Connector 705891 Qty 1 ...

Page 27: ...3 9 SECTION 3 PARTS ELECTRICAL GROUP Horn 007670 Qty 1 Electronic Foot Pedal 013877 Qty 1 Fuses F2 and F3 10 Amps Type AGC 403342 Qty 2 Fuse F1 500 Amps Type ANN 706414 Qty 1 ...

Page 28: ...3 10 SECTION 3 PARTS ELECTRICAL GROUP Strobe Light Amber 705868 Qty 1 Back up Alarm 705869 Qty 1 ...

Page 29: ...3 11 SECTION 3 PARTS ELECTRICAL GROUP LED Head Lights 705867 Qty 2 LED Tail Lights 705866 Qty 2 ...

Page 30: ...3 12 SECTION 3 PARTS MOTOR GROUP AC Induction Motor 705756 Qty 1 Spacer 706048 Qty 4 Mount 706046 Qty 1 ...

Page 31: ...3 13 SECTION 3 PARTS BATTERY GROUP Neoprene Cover 706354 Qty 1 Spare Battery Group 705774 Qty 1 Battery 706352 Qty 12 Hold Down pad 706275 Qty 3 Lug 404650 Qty 26 ...

Page 32: ...3 PARTS WHEEL GROUP Wheel Assembly 705980 Qty 4 Includes the following P215 75 R15 Tire 705981 Qty 1 Lug Nuts 705988 Qty 5 15 x7 Steel Rim 705978 Qty 1 Front and Rear Wheels have the same Tire Lug Nuts and Steel Rim ...

Page 33: ...3 15 SECTION 3 PARTS DROP BOX GROUP Transfer Case 706067 Qty 1 Front View Rear View ...

Page 34: ...pension 706638 Qty 1 Includes the following Coil Spring 706010 Qty 2 Trailing Arm Left 706030 Qty 1 Trailing Arm Right 706031 Qty 1 Shock Absorber 706009 Qty 2 Ball Joint 706012 Qty 2 Front Axle 705991 Qty 1 Tie Rod End LH 706086 Qty 2 Tie Rod End RH 706085 Qty 2 ...

Page 35: ...N 3 PARTS AXLE AND SUSPENSION GROUP Trailing Arm Left 706030 Qty 1 Includes the following Trailing Arm Right 706031 Qty 1 Includes the following Trailing Arm Bushing 706032 Qty 2 Trailing Arm Bushing 706032 Qty 2 ...

Page 36: ... 706639 Qty 1 Includes the following Shock Absorber 706009 Qty 2 Rear Axle 705990 Qty 1 Rear Axle is modified to include Axle 705992 and Spring Seat 706663 Leaf Spring 706536 Qty 2 U Bolt Kit 706049Qty 4 Note Listed quantities are for entire assembly same on both sides ...

Page 37: ...3 19 SECTION 3 PARTS STEERING GROUP Steering Shaft Bearing 706068 Qty 1 Steering Box 705983 Qty 1 Steering Quickener 706897 Qty 1 Upper Steering Shaft 706920 Qty 1 ...

Page 38: ...3 20 SECTION 3 PARTS DRIVELINE GROUP Rear Driveshaft 706014 Qty 1 Front Driveshaft 706017 Qty 1 Motor Driveshaft 706016 Qty 1 ...

Page 39: ...KE GROUP Master Cylinder 706783 Qty 1 Brake Minimum Pressure Valve 706537 Qty 1 Brake Proportioning Valve 705999 Qty 1 Park Brake Cable Center 706567 Qty 1 Park Brake Cable Left 706569 Qty 1 Park Brake Cable Right 706568 Qty 1 ...

Page 40: ...3 22 SECTION 3 PARTS BRAKE GROUP Park Brake Lever 706236 Qty 1 Front Brake Pad Kit 706738Qty 1 Rear Brake Pad Kit 707018 Qty 1 ...

Page 41: ...3 23 SECTION 3 PARTS OPTIONS LED Backup Lights 704070 Qty 2 ...

Page 42: ...3 24 SECTION 3 PARTS OPTIONS Driveline Brake Caliper 706667 Qty 1 Driveline Brake Lever 706661 Qty 1 Driveline Brake Cable 706662 Qty 1 ...

Page 43: ...intenance or detailed repair information New personnel must be thoroughly trained by qualified personnel and must never service the machine unsupervised Information in this manual must be reviewed and understood before servicing this machine Failure to comply could result in serious injury or death In addition to all safety measures outlined in this manual personnel shall adhere to all applicable ...

Page 44: ...g the machine disposal of machine fluids may be necessary Always follow applicable mine procedures and dispose of hazardous waste properly 1 Take a driveline oil sample to check the condition of the oil Based on the sample taken take appropriate corrective action to ensure the system is clean and free of damaging oil properties 2 Refer to the cleaning section and pressure wash the exterior of the ...

Page 45: ...AL SURFACES Cleaning Follow automotive practices to care for your vehicle painted metal surfaces Use a high quality automotive wax regularly to maintain the factory look of your vehicle s painted surfaces Repairing Minor Scratches surface scratch 1 Clean area to be repaired thoroughly Avoid damage Do not use rubbing compound on painted surfaces 2 Use automotive polishing compound to remove surface...

Page 46: ...heel lug nuts evenly in proper sequence 1 2 3 4 and 5 until snug 2 Finish tightening to 90 N m 65 lb ft using a torque wrench BATTERY SERVICE Battery Removal and Installation Always keep battery male connector stored inside the main disconnect cabinet when the battery is removed from the machine Failure to do so could result in damage to the connector when the battery is inserted The battery pack ...

Page 47: ...he normal charge cycle Once the battery is as fully charged as possible start the conditioning equalizing charge For maximum battery life a battery must be recharged to 100 capacity Recharging to less than 100 may result in premature battery failure Batteries are not covered under warranty if they are not recharged properly An electronic copy of the Material Safety Data Sheet MSDS for the battery ...

Page 48: ... the motor BRAKE PEDAL ADJUSTMENT It may be necessary to limit the brake pedal travel Adjustment of the brake pedal travel can be accomplished by adjusting the nut on the stop bolt on the back of the brake pedal BRAKE ADJUSTMENTS Periodically it may be necessary to adjust the park brake or the driveline brake Adjustment of these brakes can be accomplished by rotating the adjustment knob clockwise ...

Page 49: ...erate Lights Horn and Backup Alarm Check Tire Pressure Check Tire Wear Check Seat Belts Clean Operators Cab EVERY 50 HOURS Check and Tighten Hardware Clean Motor Compartment Check Motor Controller and Converter Lubricate all Grease Points Check Battery Pack Check Axle Oil Level Check Transfer Case Oil Level EVERY 100 HOURS Lubricate all Grease Points Check Brake Lines and Cables Check Fire Extingu...

Page 50: ...BRICATION Transfer Case Sight Tube Use to inspect driveline oil Transfer Case 1 Driveline Oil Tie Rod Bushings 4 Multi Purpose Grease Front Axle 1 Axle Gear Oil Trailing Arm Ball Joints 2 Multi Purpose Grease Rear Axle 1 Axle Gear Oil ...

Page 51: ...CE SERVICE LUBRICATION Motor Drive Shaft 2 Multi Purpose Grease Front Drive Shaft 2 Multi Purpose Grease Rear Drive Shaft 2 Multi Purpose Grease Master Cylinder 1 Brake Fluid Steering Shaft Bearing 1 Multi Purpose Grease ...

Page 52: ...el Bolt Torque Specifications Standard Dry Torque in Foot Pounds Bolt Size Inches Coarse Threads inch SAE Gr 0 1 2 SAE Gr 3 SAE Gr 5 SAE Gr 6 SAE Gr 7 SAE Gr 8 1 4 20 6 9 10 12 5 13 14 5 16 18 12 17 19 24 25 29 3 8 16 20 30 33 43 44 47 7 16 14 32 47 54 69 71 78 1 2 13 47 69 78 106 110 119 9 16 12 69 103 114 150 154 169 5 8 11 96 145 154 209 215 230 3 4 10 155 234 257 350 360 380 7 8 9 206 372 382 ...

Page 53: ...CE Electrical Schematic 706061 1 Rev C For more information regarding faults and warnings refer to Chapter 7 of the Sevcon Controller Manual Note A full size print of this diagram is also included separate from your manual ...

Page 54: ...4 12 SECTION 4 SERVICE Electrical Wiring Diagram 706061 2 Rev C Note A full size print of this diagram is also included separate from your manual ...

Page 55: ...r Please Specify If you experienced any problems were they resolved to the customer s satisfaction Yes __________No __________ Please indicate below your overall level of satisfaction with Oldenburg Group Incorporated and its divisions as a supplier of your equipment Place an X or check mark next to the statement that best fits your opinion Rating Description Completely Satisfied OGI Exceeded Expe...

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Page 57: ...r location designated by OGI of any product or parts of products manufactured by OGI and covered by this warranty which shall within twelve 12 months or two thousand 2 000 hours whichever occurs first after delivery to the original Purchaser be returned to OGI with transportation charges prepaid and which OGI examination shall disclose to its satisfaction to be defective All replacement parts shal...

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Page 60: ...5 542 5080 Perry Neel Office 807 221 4670 Cell 705 542 7210 Torox International Ltd Carter Kosick Office 902 468 7666 Cell 902 497 1334 MEXICO Sales Marcos Rosiles Tels 52 492 925 1668 925 1679 52 492 998 1979 Inside Mexico 01 800 831 0565 Service Manager Gabriel Rodriguez Cell 52 492 105 2162 Service Manuel Reyes Cell 52 492 105 2172 Service Jesus Fernandez Cell 52 492 126 1151 For Parts Assistan...

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