SEA ISUZU FSR Owner'S Manual Download Page 7

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OWNER

’

S MANUAL

(

SEA ISUZU FSR/FSD EV)

SEA-OWS-QA-004/5

ISSUE DATE:

30/05/2020

Page

SEA-Drive® layout and components

Components shown on below figure, may have been modified and improved in position on the chassis
based on different variations.

Overall Chassis Layout

WARNING:

The EV Component Box contains many of the HV Electrical components
and wiring for the SEA-Drive® system.

It should only be opened by SEA-Drive® technicians or qualified Electrical
tradespersons.

•

Drive motor

•

Cooling Box

•

Air compressor

& Power Steering unit

•

EV Component box

•

Drive Motor Controller

•

SEA Power Li-Ion Batteries

•

Cab Heater

Summary of Contents for ISUZU FSR

Page 1: ...OWNER S MANUAL SEA ISUZU FSR FSD EV SEA Electric Pty Ltd 13 Advantage Drive Dandenong South Victoria Australia 3175 T 613 9706 8489 ABN 42 618 821 346 ...

Page 2: ...ket 18 Disconnecting the Charge Cable 21 Kwik Portable Charger 22 6 Pre Start Checks 26 7 Driving the Vehicle 27 Starting the SEA Drive Vehicle 27 Driving the SEA Drive Vehicle 28 Regenerative Braking 29 8 Parking the Vehicle 30 9 Maintenance 31 Maintenance free 24V Battery 33 Fuse Box FB01 35 Relay Box FB02 36 10 Inspection and Service Scheduling 37 11 Trouble Shooting Guide 39 12 Towing Procedur...

Page 3: ...anical photocopying recording or otherwise without the prior written permission of the publisher This includes text pictures and tables To become familiar with the vehicle it is necessary to read and understand the Owner s Handbook and all additional literature that is part of your vehicle s documentation pack It is your responsibility to ensure that all the documentation stays with the vehicle Th...

Page 4: ...EA Drive vehicle isolating the SEA Drive vehicle s low voltage battery system will prevent the EV control system from powering up and ensuring the High Voltage system remains isolated refer below Low Voltage Isolation The Low Voltage Isolation switch is located next to the low voltage batteries Position of the batteries is based on the truck chassis Never attempt to open a battery pack This vehicl...

Page 5: ...during Operation If the SEA Drive vehicle was to lose electrical power while the vehicle is in motion the steering will become stiff and the vehicle will continue to roll The regenerative braking system will not assist braking Use of the park brake will affect braking on the rear wheels only IMPORTANT The traction battery pods will remain charged even when switched off The battery pods will remain...

Page 6: ...orque control system providing variable speed drive with regenerative braking Batteries 136kWh Lithium Ion NMC Charger Fully automatic on board 415V 3 phase 32A 22kW maximum charge approximately 6 hours IEC 62196 Charging Protocol Ancillary Electrics 3kW 24V DCDC Converter Range Up to 300km between charges unladen The location and layout of the SEA Drive vehicle and its SEA Drive components are sh...

Page 7: ...on the chassis based on different variations Overall Chassis Layout WARNING The EV Component Box contains many of the HV Electrical components and wiring for the SEA Drive system It should only be opened by SEA Drive technicians or qualified Electrical tradespersons Drive motor Cooling Box Air compressor Power Steering unit EV Component box Drive Motor Controller SEA Power Li Ion Batteries Cab Hea...

Page 8: ... of their useful life the high voltage batteries will be traded exchanged with new high voltage batteries resulting in the depleted high voltage batteries being returned to the manufacturer for secondary use This process may incur shipping handling and tax costs and will be facilitated by SEA Electric at the time of replacement ...

Page 9: ...OWNER S MANUAL SEA ISUZU FSR FSD EV SEA OWS QA 004 5 ISSUE DATE 30 05 2020 Page 9 of 56 EV Component Box AC Compressor HV Distribution Box On board Charger Charger Cable Connector Fuse Box Inverter ...

Page 10: ...OWNER S MANUAL SEA ISUZU FSR FSD EV SEA OWS QA 004 5 ISSUE DATE 30 05 2020 Page 10 of 56 Air Compressor and Power Steering Systems Drive Motor Controller ...

Page 11: ...OWNER S MANUAL SEA ISUZU FSR FSD EV SEA OWS QA 004 5 ISSUE DATE 30 05 2020 Page 11 of 56 Cooling System ...

Page 12: ...topping Vehicle must be in this position to start DRIVE Push Lever forward to select DRIVE Select for Forward operating motion REVERSE Pull Lever back to select REVERSE Select for Reversing operating motion Drive Mode Selector Drive Mode Selector 2 3 position Lever to select Drive mode NEUTRAL Middle Position Select when Parking Stopping Vehicle must be in this position to start DRIVE Push Lever b...

Page 13: ... a digital read out ECO Meter Meter shows the amount of power being drawn or added back into the High Voltage battery Acceleration will cause meter to ascend in RED Regenerative Braking will cause the meter to descend in GREEN Estimated Range Figure shows estimated travel distance until vehicle is needing to be recharged Figure is indicative only and driver should not plan trip based on figure Est...

Page 14: ...ve and will turn red if the park brake is on when trying to drive States shown are D Drive N Neutral R Reverse Regen Active Shows when regenerative braking is available White and when Regenerative braking is being applied Green Vehicle Fault Indicators Various Symbols will appear in the event of a system fault failure A reference of each fault can be found by tapping the centre of the screen SEA 2...

Page 15: ...05 2020 Page 15 of 56 Charging Mode 32A Charge Speed Charge current supplied by the in cord charger Battery State of Charge SOC Indicated by the bar numerical percentage Battery percentage is indicative only Drivers should return to a charge port when vehicle is near 5 ...

Page 16: ...le Supply Equipment it may cause fuse trip as well as charger damage Charger equipment should be kept into the isolated box or in the CAB The SEA Drive vehicle is recharged by connecting the approved wall or portable charger to the truck charging point See Appendix B at the end of manual as SEA Drive wall charger requirements Park the vehicle safely within reach of a wall socket with the above spe...

Page 17: ... 17 of 56 EVSE IEC 62196 equipment maintains a safety circuit between the mains 3 phase supply and the vehicle If this circuit is broken the mains supply is automatically isolated at the mains for the protection of all EV Charger Connection on Component Box Charger Cable Connector ...

Page 18: ...cted but no mains power supply detected Check Mains Power Supply availability and circuits Yellow or Light green Cable is connected SEA Drive vehicle is charging Green Cable is connected Batteries are fully charged Note 1 Once full charge is reached the SEA Drive system automatically shuts down to stop any residual load on the battery systems 2 Green LED is extinguished 3 SEA Drive system periodic...

Page 19: ... Description SOLID Red Cable is connected but no mains power supply detected Check Mains Power Supply availability and circuits FLASHING Green Cable is connected SEA Drive vehicle is charging SOLID Green Cable is connected Batteries are fully charged Note 1 Once full charge is reached the SEA Drive system automatically shuts down to stop any residual load on the battery systems 2 Green LED is exti...

Page 20: ...Solid Charge Complete Vehicle charge cycle has been complete The charge inlet LED will extinguish after some time Note 4 Once full charge is reached the SEA Drive system automatically shuts down to stop any residual load on the battery systems 5 Green LED is extinguished 6 If SEA Drive system remains plugged in after completing charge the SEA Drive charge circuits will periodically energize to bat...

Page 21: ...g process but the SEA Drive system will not power up until the charge cable is physically disconnected from the truck If for any reason the charge socket will not disengage when the vehicle ignition is activated the charge socket has an emergency release toggle on the rear First the vehicle isolator switch should be disconnected and removed from the vehicle to de energise all power The charge cord...

Page 22: ...MANUAL SEA ISUZU FSR FSD EV SEA OWS QA 004 5 ISSUE DATE 30 05 2020 Page 22 of 56 Kwik Portable Charger SEA Drive vehicle may be equipped with the Kwik portable charger as following details Kwik Portable Charger ...

Page 23: ...ty IP Rating IP65 Meets Standard IEC 62752 CE Approved Operating Temperature 25 C to 50 C To use the EV Charger plug the orange connector into a 5 pin 32A wall socket ensure power if off before plugging in anything Once plugged in screw the connector into place so it cannot be removed Turn on the power to see the OLED display light up Choose your charge settings and plug into the SEA Drive Charge ...

Page 24: ...OWNER S MANUAL SEA ISUZU FSR FSD EV SEA OWS QA 004 5 ISSUE DATE 30 05 2020 Page 24 of 56 Functions ...

Page 25: ...atus The following states show the correct working operating conditions of the EV Charger Fault Codes The following states show potential fault codes that may occur during operation If for any reason the charger reports the Non Automatic Recovery Fault States contact SEA Electric 24 7 support ...

Page 26: ...checks Lock and secure cab tilting locks at back of cabin Compressor oil level check air assist brake vehicles only Power steering fluid check Coolant level check at the cooling reservoir Tail lift stowed if applicable DO NOT attempt to drive if defects are found during this initial inspection Report any defect found to your supervisor manager Before attempting to drive the vehicle ensure you know...

Page 27: ...ill illuminate Drive Motor warning light is illuminated Turn the key to the START position and hold for 1 second to power up the SEA Drive Electric Drive system Let the key return to the ON position and the SEA Drive commences its power up sequence Power up sequence is complete in two to three 2 3 seconds Drive Motor warning light extinguishes once powerup is successfully completed 1 Switch or lea...

Page 28: ...lect either Drive or Reverse from the Drive Selector Note Brake pedal must be depressed or the SEA Drive will not engage selector will move Release the parking brake and operate the vehicle using the accelerator and brake as for any other commercial vehicle Note Neutral can be selected at any time by moving the selector lever No foot on brake required ...

Page 29: ...ive braking effort is applied ensuring that maximum energy recovery is achieved for the vehicle The SEA Drive vehicle also makes uses of the exhaust brake retarder stalk which can be found on the left side of the steering column same side as the wiper function By pulling the stalk down towards the driver a heavy regenerative brake can be applied without the use of the brake pedal A green light on ...

Page 30: ...e mode selector Turn the ignition key to the LOCK position Switch off all lights and radio when safe to do so Park Brake location Note Lights and radio will consume electric energy of the 24V system The charge of the 24V system batteries should never be below 22V If less than 22V the vehicle may not start Connect the vehicle to a charging socket whenever the vehicle is not being used for extended ...

Page 31: ...nted in the below figure Check that the coolant level for the drive system meets the mid level as premium Top up if required with a 50 50 glycol pre mix Coolant Reservoir Heater Reservoir Heater fluid check is completed by observing the hose and cap at the right hand rear of the truck cabin Fluid level Should be between MIN MAX level of the reservoir in the below figure Check the cold level for th...

Page 32: ... check for loose connectors and corrosion Traction batteries The Li ION traction batteries need to be discharged to below 15 once a month followed by a complete recharge This complete discharge charge cycle will also help prolong the batteries Discharge the traction batteries to below 15 monthly to prolong battery life ...

Page 33: ... Inspect if the air hole is blocked If so remove the foreign matter but do not hurt the exhaust hole Inspect if the tray is corroded If so disconnect the battery in specified order and then remove the foreign matters Then install the battery on the truck If the battery tray is seriously corroded the electrolyte may flow out due to damaged battery or abnormal electric system therefore inspect if th...

Page 34: ... reached the specified charging duration The battery voltage has been detected for 1 hour and it will not increase any more Avoid the battery from over discharging Following condition may cut short service life of battery that cause failure of starting up the drive motor therefore users are required to follow below rules Do not use the lights for a long time when the truck is OFF Charge the batter...

Page 35: ...ating Description F1 10A 24V MCU Unswitched Supply F2 10A 24V MCU Switched Supply F3 15A 24V Inverter Unswitched Supply F4 15A 24V LV DC DC 24V to 12V Unswitched Supply F6 10A 24V Air Compressor Cooling Fan Supply F7 5A 24V VMU Unswitched Supply F8 5A 24V VMU Switched Supply F13 20A 24V Radiator Fan 1 Supply F14 20A 24V Radiator Fan 2 Supply F16 10A 24V BMS Unswitched Supply F17 3A 12V HV Heater S...

Page 36: ...C D E F 1 R1 R6 2 3 R2 R7 4 5 R3 R8 6 7 R4 R9 8 9 R5 R10 10 SEA Drive Relay Box FB02 Layout Ident Coil Part Description R1 24V SEA 025 Reverse Lights R2 24V SEA 025 Inverter R3 24V SEA 025 Charge Mode for BMS R5 24V SEA 025 Pressure Relief Valve R6 12V SEA 026 12V Switched Power Caution 12V Coil R7 24V SEA 025 Heater Pump R8 24V SEA 025 Vacuum Pump Air Compressor Fan R10 24V SEA 025 Cooling Pump S...

Page 37: ...nths after previous inspection whichever comes first 270 000 or 6 months after previous inspection whichever comes first 300 000 or 6 months after previous inspection whichever comes first 330 000 or 6 months after previous inspection whichever comes first 360 000 or 6 months after previous inspection whichever comes first 390 000 or 6 months after previous inspection whichever comes first 420 000...

Page 38: ...ension A Air Compressor Replace air compressor oil check for leaks Clean replace compressor silencer and air filter Power Steering Replace hydraulic fluid in power steering system B Hydraulic Brake Booster Replace Hydraulic Fluid C Brake Fluid Replace brake fluid and bleed air from system A Air dryer Replace air dryer desiccant cartridge Cooling System Replace coolant in primary cooling system and...

Page 39: ...tor fans are not running Check Low voltage fuse as per diagram FB01 If fine check connectors are ok The Cooling pump is not running Check Relay is in correctly as per diagram FB02 If fine check connectors are ok Poor braking performance Fault diagnosis Handling methods Vacuum pump failure For vacuum over hydraulic system only Ensure that vacuum pump is running when ignition is turned on Check fuse...

Page 40: ... as per diagram FB02 The front tire pressures are low Adjust to specified pressure Excessive free play in steering Fault diagnosis Handling methods Front tyre pressures are low Adjust to specified pressure Free play in steering box Refer to OEM for adjustment replacement Kingpin bearings are worn Refer to OEM for replacement Worn bushes in steering linkage Refer to OEM for replacement The ball joi...

Page 41: ... ground Caution Ask tow operators to do one of the below methods for your vehicle Alternative1 Disconnect Prop Shaft from diff or completely remove Alternative2 Remove the drive shaft from the diff Preferred method Release the parking brake and shift the gearshift lever to neutral gear The maximum towing speed is 65km h when the rear wheels are on the ground Warning Do not tow vehicle with driven ...

Page 42: ...l side socket to the wall plug Ensure that the wall socket is safely locked into the wall plug by rotating the orange locking mechanism 2 3 4 5 6 Park the vehicle safely next to the charging point Put the Gear Selector to N position and apply Park Brake to prevent any potential movement The vehicle s charging inlet is located on the component box at the side of the vehicle Turn the vehicle ignitio...

Page 43: ...at the vehicle side socket lights up YELLOW This shows that the charging process in now underway LED colour may be yellow or light green Charging Process 7 10 Remove the cap and plug the charging connector Vehicle side socket to the charging inlet This will lock automatically Phase Step Safe Operating Procedure Note Photo Instruction Turn the wall plug ON 8 Once powered ON check that the juice boo...

Page 44: ...tric Vehicle Supply Equipment is completely removed Caution In the event of a charging fault and to release the vehicle plug from the vehicle inlet open the component box and turn the vehicle socket pin to the unlock position This will then allow you to release the plug from the vehicle WARNING Ensure that the wall charger switch is OFF Failure to do so may result in death or serious injury 15 Tur...

Page 45: ...e vehicle side socket LED Colour Red Cable is connected but no mains power supply detected Check Mains Power Supply availability and circuits Yellow Cable is connected Vehicle is charging Green Cable is connected Batteries are fully charged Unlit Cable is not properly connected SEA Drive Charging Procedure SOP NO SOP SD 001 Rev 1 Page 4 4 Model SEA Drive Variation AS NZ Trucks Issue Date Aug 2019 ...

Page 46: ...s in the OFF position Wall plug specification must be 3 Phase 5 pin 32Amp Charger Plug in Process Page 0 Issue Date AS NZ Trucks Rev Variation SEA Drive Connect the charger wall side socket to the wall plug 2 3 4 5 Park the vehicle safely next to the charging point Put the Gear Selector to N position and apply Park Brake to prevent any potential movement The vehicle s charging inlet is located on ...

Page 47: ...to 32 amperes 9 Open the charging inlet flap on the component box Located at the component box found on the side of the vehicle On opening the vehicle charging cap look for dirt debris and foreign objects Clean before connection if needed NOTE Charger on the truck component box is never live just for power input and will not output power The vehicle side socket will light up White on the left LED ...

Page 48: ...release If the charging process needs to be interrupted prior to the battery reaching 100 full state simply turn the ignition key to the ON position and the socket will be released automatically 15 Remove the charging cable from the socket at vehicle side IMPORTANT The vehicle cannot be started while charging It means the vehicle physically unable to move until the EVSE is completely removed Cauti...

Page 49: ...t to prevent any power drain of the LV batteries Remove the cable from the vehicle side socket White Unlit Red Cable is connected but no mains power supply detected It will turn to Unlit Red after 5 10 seconds which shows an error Check Mains Power Supply availability and circuits Flash Green Cable is connected Vehicle is charging Unlit Red Cable is connected but no mains power supply detected It ...

Page 50: ...that batteries are placed on charge prior to depleting beyond 10 and that they charged to full state of charge Sep 19 1 Note Photo Step Phase Safe Operating Procedure Instruction SOP NO Model 1 4 SOP SD 004 Prepare the charging cable for connection to 3 phase power supply outlet The charging cable supplied by SEA Electric may vary Inspect the charging cable for any damage prior to use Cut or chafi...

Page 51: ...ows that the charging process in now underway Only flashing indicates charging is working If the LED is solid GREEN or Unlit refer to your owners manual Charging Process 7 10 Remove the cap and plug the charging connector Vehicle side socket to the charging inlet This will lock automatically Phase Step Safe Operating Procedure Note Photo Instruction Turn the wall plug ON 8 Once powered ON check th...

Page 52: ...ging inlet of the vehicle IMPORTANT The vehicle cannot be started while charging It means the vehicle physically unable to move until the EVSE Electric Vehicle Supply Equipment is completely removed Caution In the event of an emergency and to release the vehicle plug from the vehicle inlet locate the release cable to the unlock position This will then allow you to release the plug from the vehicle...

Page 53: ...supply applied System fault occurred Contact SEA Electric Flashing Red Cable is connected mains power not yet applied System initializing Vehicle is charging Solid Green Cable is connected Batteries are fully charged Unlit Cable is not properly connected Flashing Green Cable is connected SEA Drive Charging Procedure Alternate Mounting SOP NO SOP SD 004 Rev 0 Page 4 4 Model SEA Drive Variation AS N...

Page 54: ...20 5 3 500 32 32 5 32A 3phase 5 pin Wall Switch 20A 3phase 5 pin Wall Switch Wall Plug Matching Plug Straight Matching Plug Angle ISOPS520P ISOPA520P ISOPS532P ISOPA532P Refer to AS NZS3000 2018 for wall inlet cable sizing and safety equipment Refer to New Zealand Worksafe Guidelines for safe electric vehicle charging https worksafe govt nz laws and regulations regulations electrical regulations r...

Page 55: ...Manual service disconnect can be found on all generation 4 battery pods on older models this may be missing In this case removal of the 12 24V battery should open the high voltage connectors Turn the vehicle ignition OFF Remove the key to secure the vehicle 3 4 5 Only remove the manual service disconnect if step 1 and 2 have been done and wait 5 sec after step 2 before removing Power Down Battery ...

Page 56: ...laws and regulations when being a first or second responder The maximum towing speed is 65km h when the rear wheels are on the ground 7b Else place vehicle onto a flat bed tow truck Note Photo 8 Use water to fight a high voltage battery pack fire Continuously use large amount of water on high voltage battery pack until no heat can been seen coming from the battery pack with a thermal camara There ...

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