Tomberlin 2010 E-Merge Maintenance Manual Download Page 130

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Battery and Charger

MERGE 11-23

Chapter 11

Fig 11-16: diode test procedure

Fig 11-17: lester full automatic controllable silicon charger wiring diagram

Fig 11-15: Charger trouble-shooting procedure

Summary of Contents for 2010 E-Merge

Page 1: ... Tomberlin assumes no liability for the content provided in this consumer educational section and it is possible that an error with regard to spelling grammar nomenclature and translation is present Note that the information provided should be treated as live documents meaning they are always in a state of refinement correction and improvement Check back often and if printed check back prior to re...

Page 2: ......

Page 3: ...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 of t...

Page 4: ...nd Assembly 1 7 Chapter 2 Regular Inspection and Adjustment Regular Maintenance 2 1 Periodic Lubrication Plan 2 2 Braking System 2 4 Braking Inspection 2 4 Inspection of Parking 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 Fro...

Page 5: ...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 6: ...ry discharge meter removal 9 2 Battery discharge meter installation 9 3 Horn removal 9 3 Horn installation 9 3 Combination switch removal 9 4 Combination switch installation 9 4 Controller removal 9 5 Controller installation 9 6 Charger receptacle removal 9 7 Charger receptacle installation 9 7 Battery removal 9 7 Battery installation 9 8 DC converter removal 9 8 DC converter installation 9 8 Remo...

Page 7: ...cedure 7A Pin 1 10 7 Check Procedure 7B Pin 4 and 5 10 8 Check Procedure 7C Pin 7 10 9 Check Procedure 7D Pin 6 10 9 Check Procedure 7E Pin 3 10 9 Check Procedure 8 voltage at the red wire jack of charger receptacle 10 10 Check Procedure 9 Motor speed sensor 10 10 Check Procedure 10 forward reverse gear switch 10 11 Check Procedure 11 Reverse buzzer 10 11 Check Procedure 12 Battery discharge meter...

Page 8: ...tery 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 Troubleshooting 11 19 Diode test procedure 11 20 Procedures for component replacement 11 20 Charger trouble shooting procedure 11 20 On board charger 11 23 Operating Instructions 11 23 Maintenance in...

Page 9: ...eed sensor magnet 12 7 Mounting of the speed sensor magnet 12 7 Readjustment of the electric motor 12 7 Specifications for the electric motor 12 8 Assembly of the electric motor 12 9 Mounting of the electric motor 12 11 Speed sensor of the electric motor 12 14 Inspection of the speed sensor of the electric motor 12 14 Removal of the speed sensor 12 14 Mounting of the speed sensor of electric motor...

Page 10: ...ld 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 ...

Page 11: ...accidents 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 wo...

Page 12: ... marks 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...

Page 13: ...olation 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 14: ...ase arrange and fix the wiring and wiring harness Inappropriate arrangement of the wiring and wiring harness may result in the malfunction of the vehicle property damage and or personal injury and death Use the Designated Lifting 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 vehicl...

Page 15: ... Instrumentation 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 t...

Page 16: ...g of bearing 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 Disassembl...

Page 17: ...00 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 f...

Page 18: ...nd 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 inspecti on Inspect the parking pedal for free travel and make adjustments when necessary CA CA CA I...

Page 19: ...se Charger receptacle 4 NYE760G Front suspension 5 3 Lithium based grease Front stub axle 7 Lithium based grease The user or trained technician applies the lubricating oil once a quarter every 50 working hours Braking grease cup 8 DOT3 3000 brake oil Inspect the driving axle oiled cork position 6 32 8 ounce 1 1 liter 37OZ lubricating oil GL 5 The trained technician applies the lubricating oil once...

Page 20: ...ping 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 21: ...t Defects are to be replaced Free Travel of the brake pedal 13mm 0 512 in Inspection of Parking Brake 1 Turn the key switch to OFF position and take out the key 2 Remove the protecting jacket of brake handle 1 Inspect Parking brake ratchet Ratchet brake Worn or damaged ones are to be replaced 2 Measure Free travel 15mm 0 591in In case of non compliance with the standard adjustment is to be made ...

Page 22: ...of the front tires Lift the rear body with the lifting jack 3 Remove the rear tire 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 th...

Page 23: ...mum 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 7 0 mm 0 16in Maximum thickness wearing valu...

Page 24: ... 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 25: ...in 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 ...

Page 26: ...b 3 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 27: ...e the bushing is to be replaced or the bearing clearance is to be 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 0...

Page 28: ...e rod so that the length between two ball joints decreases toe in 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...

Page 29: ...e Main 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 re...

Page 30: ...he 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 31: ...o seize 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 32: ...bolts 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 33: ...ures 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 34: ...Canopy MERGE 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 35: ...umper 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 36: ...val 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 37: ...rest 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 38: ...on page 3 1 Instrument panel Rubber 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 39: ...ion sheath Fixing rubber nail on the upper dashboard Fixing bolt on the lower dashboard Disengage the 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 ...

Page 40: ...steering 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 Rubber nail Screw Rear tray Refer to Removal of Rear Tray on page 4 1 3 Disconnect Rear light connecting line ...

Page 41: ...xing 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 42: ...Rear 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 43: ...aring 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 44: ...of Lifting Jack 5 Remove Front wheel nut Front wheel 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 b...

Page 45: ...apter 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 46: ...4 mm 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 47: ...Removal 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 48: ...ding 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 connect...

Page 49: ...ket 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 ...

Page 50: ...rim 12 Air valve 13 Tire 14 Wheel rim decorative cover 15 Retaining plate 16 Bearing 6206 17 Bearing fixing bush 18 Oil seal 19 Spring washer 20 Flat washer 21 Brake rocker arm 22 Locating dowel 23 Wheel cylinder 24 Locating dowel 25 Upper tension spring 26 Lower tension spring 27 Wheel nuts 28 Return spring 29 Bolt 30 Spring washer 31 Bolt 32 Spring washer 33 Nut 34 Bolt 35 Clipping spring 36 Bol...

Page 51: ...f Designated 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 Six 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 ...

Page 52: ... rear 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 ...

Page 53: ... pincer 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 54: ...formation 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 recomme...

Page 55: ...l surface of the bearing Basic grease 2 Install Brake base plate Half axle assembly of rear axle Bolt Spring Nut Tightening torque 22N m 16 2 ft 1b 3 Install Half axle outer tube of rear axle Bolt Tightening torque 60N m 44 3 ft 1b 4 Install Brake shoe Upper tension spring Lower tension spring 11 Locating dowel Clipping spring ...

Page 56: ...RNING 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 nut of rear wheel Tightening torque 70N m 51 7 ft 1b 6 Install Bleeding bolt Tightening torque 70N m 51 7ft 1b Remarks Apply 1100mL lubricating oil GL 4 or GL 5 to the rear axle 7 Install Oil filler screw plug ...

Page 57: ... Middle shaft 6 Oil filler plug 7 Ring gear 8 Differential gear 9 Bearing pressing block 10 6008 bearing 11 Bearing 6303RS 12 Bearing 6005RZ 13 Inner clasp 14 Rubber cover 15 Gear bush 16 Oil seal 17 Bearing bush 18 Bolt 19 Spring washer 20 Bolt 21 Copper washer 22 Spring washer 23 Bolt 24 Stud bolt 25 Nut 26 Bleeding bolt ...

Page 58: ...m cover of differential gear Caution The bottom cover of the differential gear should be pried up by a flat head screwdriver Please note not to damage the sealing surface of the box or deform the bottom cover of the differential gear 2 Remove Bearing pressing block bolt Bearing pressing block Differential with ring gear and bearing ...

Page 59: ...emble Ring gear Differential gear assembly 4 Remove Sealing rubber cover both ends 5 Remove Oil seal Clip spring Bearing fixing bush Bearing Input shaft 6 Remove Clip spring from countershaft gear Bearing Gear bush Countershaft Countershaft gear ...

Page 60: ...e the countershaft gear on the other side Inspection 1 Inspect Ring gear Differential gear assembly In case of damage or abrasion replacement is to be made Bearing In case of erosion damage replacement is to be made Install In the reverse order of the removal procedure Note the following 2 Tighten Differential gear bolt that connects the ring gear and differential gear assembly Tightening torque 5...

Page 61: ...erential gear surface and 10 bolt holes 4 Tighten Differential gear bottom cover bolt NOTICE Tighten the bolts diagonally from the smallest type in two phases Install In the reverse order of the removal procedure and note the following 1 Install Rear axle and rear rocker U bolt Tightening torque 50N m 36 9ft 1b 2 Apply Oil Recommended oil GL 4 or GL 5 gear oil Oil volume 1100mL ...

Page 62: ... master cylinder 7 Brake drum 8 Boot 9 Brake pedal base 10 Brake pedal sealant 11 Brake shoe plate 12 Brake handle base 13 Return spring 14 Nut 15 Locating dowel 16 Flat washer 17 Split pin 18 Bolt 19 Nut 20 Bolt 21 Parking switch 22 Nut 23 Bolt 24 Bolt 25 Nut 26 Cable 27 Oil hose 28 Iron oil tube 29 Bolt 30 Reservior 31 Clamp 32 Tee tube ...

Page 63: ...ective 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 replac...

Page 64: ...dle 1 Measure Free play of parking brake handle 15mm 0 591in In case of non compliance with the specification the free play is to be adjusted 2 Remove Boot 3 Inspect Hand brake cable In case of oil leakage deformation fall off replacement is to be made ...

Page 65: ...Brake System EMERGE 7 4 Chapter 7 Accelerator pedal 1 Accelerator pedal 2 Accelerator 3 Accelerator bracket 4 Pivot 5 Split pin 6 Pin axle 7 Washer 8 Split pin ...

Page 66: ...lt 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 bushin...

Page 67: ... 1 Recommendation for Use of Lifting Jack 4 Remove Steering wheel cover plate Steering wheel nuts Steering 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 n...

Page 68: ...ss the steering shaft out of the 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 Lower fixing bolt on the universal joint Tightening torque 25N m 18 4 ft 1b Universal joint...

Page 69: ...le Drag link ball joint 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 ...

Page 70: ...uld 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 ...

Page 71: ...he 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 72: ... Apply 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 shou...

Page 73: ...owly Note do not pull apart the connecting wire of the instrument panel pull out the wire of 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 6 Hold the key switch and remove the switch lock nut from outboard of instrument panel 7 Check Refer to Check Procedure 6 Circui...

Page 74: ...itch out of the housing 7 Check Continuity of the gear switch Refer to Check Procedure 10 forward reverse gear switch of Chapter 10 replace the part in case of counter conditions Installation of forward reverse gear switch Back to the removal steps NOTE The red black yellow and blue white wires must be connected correctly at relevant positions on the gear switch removal of headlight power switch 1...

Page 75: ... and lower ends of the switch push switch out of the housing check Continuity of the emergency switch Installation of emergency switch Back to the removal steps Note The red black yellow and blue white wires must be connected correctly at relevant positions on the emergency switch Installation of Battery power level indicator ...

Page 76: ...the removal steps NOTE The red red green and black wires must be connected correctly at relevant positions on the battery discharge meter Horn removal 1 Take out the key from the key switch 2 Apply the parking brake 3 Turn Tow Run switch to TOW Please refer to Chapter 1 Protection for Electrical Safety 4 Disconnect the horn wire 5 Remove the horn set bolt and remove the horn 6 Check the horn for c...

Page 77: ...e key from the key switch 2 Apply the parking brake 3 Turn Switch Tow Run to TOW Please refer to Chapter 1 Protection for Electrical Safety 4 Remove the protective sleeve for the wire harnesses of combination switch 5 Remove the set bolt from the top of the switch 6 Remove the instrument panel refer to the relevant contents in Chapter 4 7 Disconnect the wire plug in package of the combination swit...

Page 78: ...removal 1 Take out the key from the key switch 2 Apply the parking brake 3 Turn Switch Tow Run to TOW Please refer to Chapter 1 Protection for Electrical Safety 4 Remove the trunk lid 5 Remove the rear plate plastic screw 6 Remove the rear plate 7 Remove the safety belt buckle set bolt Tightening torque 63N m 46 5ft 1b 8 Remove the safety belt buckle 9 Disconnect all wires and multi wire connector...

Page 79: ...Electric Component MERGE 9 7 Chapter 9 Control circuit ...

Page 80: ...troller Controller installation Back to the removal steps Check the electric vehicle for normal operation When Forward Reverse gear switch is on FORWARD position make sure the electric vehicle is running forward When Forward Reverse gear switch is on REVERSE position make sure the electric vehicle is running backward When ...

Page 81: ...e refer to Chapter 1 Protection for Electrical Safety 4 Remove the red wire and the black wire from the positive binding post on the rear of charger receptacle 5 Screw off 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 repl...

Page 82: ...level of the 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 2 Apply the parking brake 3 Remove the seat pad assembly 4 Turn Tow Run switch to TOW Please refer to Chapt...

Page 83: ...ctrical Safety 5 Remove the watertight cover of DC changeover contactor 6 Remove the lock nut on the binding post of changeover contactor 7 Remove the connecting wire then remove the diode assembly NOTE Keep in mind the polarity of the diode to prevent incorrect installation resulting in short circuit and electric element burning out 8 Remove the DC changeover contactor 9 Check The continuity of D...

Page 84: ...ty Motor removal 1 Take out the key from the key switch 2 Apply the parking brake 3 Turn Tow Run switch to TOW Please refer to Chapter 1 Protection for Electrical Safety 4 Mark a line at the motor interface with a marking pen 5 Hold the binding post with two wrenches disconnect the wire from the connecting terminal of the motor 6 Remove the 6 bolts fixing the motor Marking line ...

Page 85: ...se Scrape off the paint to ensure a good contact Connect the red probe to terminals A1 A2 F1 and F2 respectively The multi meter should show no connection Armature circuit opening Use a multi meter set to 200Ω connect the red probe to A1 and connect the black probe to A2 The multi meter should show connection Exciting circuit opening Use a multi meter set to 200Ω connect the red probe to F1 and co...

Page 86: ...y 4 Disconnect the connecting wire of the headlight and the cable plug in package 5 Remove the 4 screws fixing the headlight with a Philips driver 6 Remove the headlight pull apart the power cord from the headlight bulb 7 Remove the 2 screws fixing the bulb with a screw driver and take out the headlight bulb 8 Turn the lamp receptacle of the front turn signal light and remove the turn signal lamp ...

Page 87: ...tch to TOW Please refer to Chapter 1 Protection for Electrical Safety 4 Remove the tail light with a flat head screwdriver CAUTION Don t break the 4 snaps on the lens the tail light must be replaced if any of them is broken 5 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 Apply the parking brake 3 Turn Tow Run...

Page 88: ...he bulb 3 Check the continuity Replace 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 2 Apply the parking brake 3 Turn Tow Run switch to TOW Please refer to Chapter 1 Protection for Electrical Safety 4 Disconnect the wiper 5 Remove the wiper arm 6 Remove the fixing nut of wipe...

Page 89: ...g brake 3 Turn Tow Run switch to TOW 4 Take off the connector of inner mirror 5 Take off fixed nut of inner mirror 6 Take out the mirror Installation of inner mirror 1 Stick the sponge glue and clip on the bracket of inner mirror 2 Fix the bracket on windshield frame 3 Take off white lense 4 Fix the mirror on the bracket ...

Page 90: ...e 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 output wire of wiper 8 fix the wires of inner mirror along the wire clip ...

Page 91: ... contact 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...

Page 92: ...ry 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 Turn si...

Page 93: ...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 A1 and A2 4 TOW RUN switch 5 Battery voltage under voltage 6 Circuit of key switch and accelerator pedal switch 7 Controller signal 8 Charger 9 Motor speed sensor 10 Forward reverse gear s...

Page 94: ...hen 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 A1 and A2 Please refer to Chapter 1 Protection for Electrical Safety 1 Jack up the rear axle of the electric vehicle so that the rear wheels are in the air 2 Check that the battery is wired correctly then conne...

Page 95: ...ltage 3 For a fully charged 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 fault...

Page 96: ...d probe to the pedal switch output wire Wire 3 9 2 When the Tow Run switch is on RUN position the key switch is ON and Forward Reverse gear switch is on NEUTRAL the voltage reading should be 0V When the accelerator pedal is depressed the voltage reading should be reference voltage 48V the battery should be fully charged 9 3 If the voltage reading is 0V when the accelerator pedal is depressed check...

Page 97: ...or speed sensor a pulse input signal provided to controller by motor speed sensor Pin 4 black yellow wire FORWARD input signal provided by Forward Reverse switch when Forward Reverse switch is on FORWARD position the switch provides a voltage of 48V to the controller Pin 5 blue white wire REVERSE input signal provided by Forward Reverse switch when Forward Reverse switch is on REVERSE position the...

Page 98: ...y a 0V DC voltage 3 While observing the multimeter turn the Forward Reverse switch to REVERSE The multimeter should display a voltage of 48V 4 Turn Forward Reverse switch to FORWARD the multimeter should display a full battery voltage about 48V 5 Insert the red probe of the multimeter into Pin 5 blue black wire of the 9 wire connector Leave the black probe connected to the negative binding post of...

Page 99: ...ire connection is correct if it is abnormal replace the accelerator Check Procedure 7D Pin 6 1 Use a multimeter set at 200V DC insert the red probe of the multimeter into Pin 6 red green wire Refer to the following Note Connect the black probe to the negative binding post of the battery pack 2 With key switch turned ON turn Tow Run switch to RUN then the multimeter should display a full battery vo...

Page 100: ...g post of the battery and connect the black probe to the Terminal 16 of the 3 wire connector The voltage reading should be approximately 0V the battery is fully charged 3 Turn Tow Run switch to RUN use a multimeter set to 20V DC connect the black probe to the negative binding post of the battery pack and connect the red probe to red wire of the 3 wire connector The voltage reading should be approx...

Page 101: ...lectrical Safety 1 Disconnect the battery cable according to the directions Please refer to Chapter 1 Protection for Electrical Safety 2 Disconnect the 3 wires from the gear switch Use a multimeter set at 200Ω connect the black probe to Position 7 or 8 of the gear switch then connect the red probe to Position 3 or 4 When the switch is on NEUTRAL or REVERSE no continuity should be indicated When th...

Page 102: ...connector 13 In case of un continuity of the brown yellow wire or improperly arranged Pin 10 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 Tow Run switch red green wire connected to key switch ...

Page 103: ... the black probe to black wire The voltage should be 12V Perform the following checks if the voltage is 0 1 Check whether the DC converter outputs a 12V voltage Check the converter for failure and replace it if necessary Continue with Step 2 if it is ok 2 Check the fuse in the fuse box and replace it if necessary If the fuse is ok go to Step 3 3 If no problem is found in the above Step 1 and 2 and...

Page 104: ...an not move forward the way of repairing will be 1 There is no failure on the cable connection such as disconnect or loosen 2 Connect the programmer choose diagnosing manual see the display on it if it says NO KNOW FAULTS then it means everything is OK 3 Choose testing manual observe the input output status for forward if the FORWARD INPUT is OFF on the testing manual then there is some failure on...

Page 105: ...ontactor welded 1 Auxiliary contactor is welded 2 The drive of auxiliary contactor is short 12 SPEED SENSOR FAULT Speed sensor failure 1 No connection on the speed sensor 2 Speed sensor is broken 13 MAIN DRIVER ON The drive input of main contactor is less currency 1 Main contactor failure or open circuit 2 controller is broken 14 MAIN COIL FAULT The coil of main contactor is failure 1 The coil of ...

Page 106: ...amage 1 Motor field cable come off 2 Motor field cable is open 26 HW FAILSAFE Automatic checking failure 1 controller is broken Picture 1 1268 controller programmer faulty code table 二 LED failure diagnosis There is LED on the controller you can see it from the window on the top of controller cover When there is any fault on the controller or the input then it will display the failure indication c...

Page 107: ...ctor is over currency 4 1 Field currency speed sensor is failure 4 2 The driving of main contactor or auxiliary is over currency 4 3 Inner M is short circuit to B 4 4 The auxiliary is delay of close 4 5 Auxiliary contactor is delay of weled 5 1 Key switch SRO failure 5 2 The coil of main contactor is open 5 3 Less currency on the coil 5 4 antislip circuit failure or antislip fuse is open circuit 5...

Page 108: ...partition 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...

Page 109: ...y Common 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 Prem...

Page 110: ... tools 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 an...

Page 111: ...in 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 th...

Page 112: ...y should 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 ...

Page 113: ...the 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 t...

Page 114: ...ry 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...

Page 115: ...batteries 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 co...

Page 116: ...readings doesn t exceed 0 7V In case the reading of any single battery is lower than 9 3V and its difference with the battery that has a voltage of over 9 3V exceeds 0 7V the battery should be replaced All the readings are higher than 9 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 specifi...

Page 117: ...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 118: ...he 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 Th...

Page 119: ...1 248 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...

Page 120: ...tes 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 down the voltages of all batteries NOTE W...

Page 121: ...e Example 1 Due to the poor performance of the electric vehicle and the battery is suspected to be the cause the battery charger is inspected When the battery is fully charged the reading on the ammeter of the battery charger is 8 0A The charging voltage inspection is conducted and the results are recorded Battery number 1 2 3 4 5 6 Charging voltage 10 15V 10 60V 9 80 V 10 16V 10 56V 10 61V As bat...

Page 122: ...n for Electrical Safety Please follow the instructions below to store the battery that will not be used for a long time 1 Keep the battery clean and rust free Please refer to battery maintenance 2 In case the battery in the vehicle is stored in winter and is not necessary to be connected with the charger the battery of the electric vehicle should be disconnected 3 Fully charge the battery before s...

Page 123: ...se 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 charge...

Page 124: ...ion 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 charg...

Page 125: ...us 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 tech...

Page 126: ...g of the auxiliary contacts of AC connector To clean the auxiliary contacts please press down the elastic connector protective sleeve See Fig 11 13 Wrap the connector with the emery paper and wipe back and forth for about 10 to 20 times Keep the pressure on the cleaned contact surface Fig 11 13 Clean the auxiliary contacts of the charger plug ...

Page 127: ...Battery and Charger MERGE 11 20 Chapter 11 ...

Page 128: ... the DVOM has no connection configuration then configure the DVOM at kilo ohm When the connection is detected the DVOM will display 0 See Fig 11 14 Fig 11 14 Continuity inspection Diode test procedure To test the diode first disconnect the AC supply of the battery charger After setting the DVOM at the highest usable ohm range attach the probe to the diode see Fig 11 16 In case the reading is not t...

Page 129: ...e into the electrical outlet Electric meter deflection Complete the inspection of the battery Transformer has sound Disconnect the AV and DV wires Replace PC circuit board and return to the beginning Replace the fuse return to the beginning Repair or replace return to the beginning Transformer has sound Transformer has no sound WARNING When the charger is connected to the power supply with housing...

Page 130: ...Battery and Charger MERGE 11 23 Chapter 11 Fig 11 16 diode test procedure Fig 11 17 lester full automatic controllable silicon charger wiring diagram Fig 11 15 Charger trouble shooting procedure ...

Page 131: ...912 xx1x single LED flashes YELLOW 4 When the battery is at approximately 80 state of charge the bulk stage has completed and an 80 charge indication is given Models 912 xx0x turn on the 80 LED and Models 912 xx1x will flash its LED GREEN on more than off In the next phase known as the absorption or constant voltage phase the last 20 of charge is then returned to the battery The charging could be ...

Page 132: ...ower for at least 15 seconds the charger must be brought to a qualified service depot Maintenance instructions 1 For flooded lead acid batteries regularly check water levels of each battery cell after charging and add distilled water as required to level specified by battery manufacturer Follow the maintenance and safety instructions recommended by the battery manufacturer 2 Make sure charger conn...

Page 133: ...he fins of the charger will reduce their heat dissipating qualities Optimal cooling also occurs when the charger is mounted on a horizontal surface with the fins vertical More airflow from below the charger will help cool the fins so mounting above open areas or areas with cut outs for airflow is desirable Contact Delta Q for information on other mounting orientations As the charger may get hot I ...

Page 134: ...C input connector IEC320 C14 require 1 8m localized cord DC output connector OEM specific w 12AWG wire Regulatory Safety EN 60335 1 2 29 Safely of Appliances Battery Chargers UL2202 EV Charging System Equipment UL1564 2nd Edition Industrial Battery Charger CSA C22 2 No 107 2 Battery Chargers Industrial Emissions FCC Part 15 ICES 003 Unintentional Radiators Class A EN 55011 Radio disturbance charac...

Page 135: ... followed by a longer pause To check change the charging algorithm a Disconnect the charger positive connector from battery pack Apply AC power and after the LED test the Algorithm will display for 11 seconds b To change algorithm touch positive connector during the 11 second display period to the battery pack s positive terminal for 3 seconds and then remove the Algorithm will advance after 3 sec...

Page 136: ...minal of the electric motor 3 Attach the black probe of the multimeter set at 200Ω ohm to the motor enclosure Scrape off the paint on the motor cover to ensure good connection Attach the red probe to the terminals of A1 A2 F1 and F2 separately see Fig 12 1 The multimeter shows not connected In case of conducting state the electric motor should be removed from the electric vehicle and be repaired b...

Page 137: ... as specified Please refer to Chapter 1 Protection for Electrical Safety 2 Secure the terminals with two spanners and disconnect wires from connecting terminals F1 and F2 of the electric motor Attach the red probe of the multimeter set at 200Ω ohm to F1 and the black probe to F2 terminal The multimeter should indicate connected In case of wrong reading the cause may be open excitation coil or poor...

Page 138: ...he armature 17 from the other end of the stator enclosure 5 Unscrew the two screws 11 securing the brush gear 12 to the end shield see Fig 12 7 6 Mark the brush terminals A1 and A2 13 to indicate their positions in the end shield Then unscrew the nut spring washer small washer and large washer see Fig 12 7 Insert the terminal into the interior of the stator enclosure through the enclosure wall 7 C...

Page 139: ...y coarse commutator can be polished by 400 or finer emery paper WARNING It is strictly prohibited to burnish the commutator with abrasive cloth The grains on abrasive cloth are conductive and may result in the short circuit of the commutator bar It is prohibited to apply oil or lubricant to the commutator or brush NOTE In case there is oil on the commuttor the oil seal of the output shaft on the d...

Page 140: ...uit coil winding In case the insulating material of the excitation winding is charred please replace the electric motor or the stator enclosure component Motor element 1 Inspect the insulator for crack or other damages see Fig 12 7 2 Inspect the brush 13 for damage or heavy wear Replace the brush when necessary 3 Inspect the brush spring 14 see Fig 12 7 Replace the spring of which the color change...

Page 141: ...placed with new one in case the bearing noise is too loud unable to rotate smoothly or the clearance is too large Inspect the bearing and replace it in case the bearing rusts is abraded or cracks or in case the color of the metal of the bearing changes abnormally Do not remove the bearing from the armature shaft unless for replacement purpose Removal of the bearing 1 Secure the bearing puller to t...

Page 142: ...sensor magnet Mount the speed sensor magnet 18 to the shaft with bolts 19 and tighten the torque of the bolts with 22 inch pound 2 5N m Readjustment of the electric motor The electric motor should be readjusted by professional motor maintenance technician The use of corresponding activities and procedures is crucial to the success of readjustment to the electric motor ...

Page 143: ...2 8 Chapter 12 Specifications for the electric motor Any readjustment must be carried out by professional technicians The maintenance specifications for the electric motor are shown in the table below Fig 12 7 Electric motor ...

Page 144: ... the connecting terminal and brush be properly aligned in the transmission gear For the mounting of brush please refer to Assembly of the electric motor Once one brush is replaced all the other brushes should also be replaced at the same time Never replace only two of them Brushes should be mounted on the same transmission gear and the two brushes connected should be symmetrically mounted 2 1 Secu...

Page 145: ... brush so that the brush holds against the commutator 3 Mount the end shield onto the stator enclosure 3 1 Align the match marks on the end shield and the stator enclosure before mounting two bolts 8 see Fig 12 10 Tighten the bolt with a torque of 7 4 foot pound 10N m 4 Ensure the free rotation of the armature In case the armature cannot rotate freely remove the electric motor to spot the problem ...

Page 146: ...xle 2 1 As shown in the figure extrude about 1 2 inch 1 3cm of NYE lubricating oil from the tube onto the putty knife see Fig 12 11 2 2 Turn the wheel so as to rotate the input shaft 2 3 Evenly apply the motor coupling grease onto the rotating input shaft Start the application from the position 1 8 inch 3 1mm lower than the shaft end to the driving axle far end of the shaft see Fig 12 12 2 4 The g...

Page 147: ...dundant grease on the input shaft towards the driving axle When the electric motor is fitted over the input shaft the clearance between the electric motor and the driving axle enclosure is about 1 16 inch 1 6mm see Fig 12 14 4 2 Mount the six bolts and washers of the fixed electric motor on the driving axle Do not tighten them 4 3 Tighten the bolts with hand 1 and 2 in the order shown in the figur...

Page 148: ...onnect 3 wire speed sensor wires and electric vehicle harness 5 In case the wheels are removed mount them and tighten the wheel nuts with fingers 6 Turn the TOW RUN switch to the TOW position To connect the battery first connect the positive electrode cable then tighten it with a torque of 110 inch pound 12 4N m Apply the antirust oil on all connecting terminals to minimize future corrosion 7 Set ...

Page 149: ...or 22 from the hardness of the electric vehicle see Fig 12 16 3 Take down the speed sensor 21 of the electric motor from the end shield of the electric motor with a screwdriver 4 Remove the speed sensor magnet 18 from the armature end with a spanner Mounting of the speed sensor of electric motor 1 Mount the speed sensor magnet and tighten the bolts with a torque of 110 inch pound 12 4N m see Fig 1...

Page 150: ...o the TOW position To connect the battery first connect the positive electrode cable then tighten it with a torque of 110 inch pound 12 4N m Apply the antirust oil on all connecting terminals to minimize future corrosion Fig 12 16 E merge electric motor speed sensor ...

Page 151: ...TOMBERLIN AUTOMOTIVE GROUP INC 3123 WASHINGTON ROAD AUGUSTA GA 30907 WWW TOMBERLIN NET 706 860 8880 ...

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Tomberlin 2010 E-Merge, Maintenance Manual

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