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Tomberlin E-MERGE 2007, Maintenance Manual, Page: 7 / 157

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Tomberlin E-MERGE 2007 Maintenance Manual Download Page 7

 

6 

Motor removal.........................................................................................................9-

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Motor installation....................................................................................................9-

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Removal o f bulb of headlight and fro nt turn signal light..................................9-

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Headlight installatio n .............................................................................................9-

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Tail light removal ...................................................................................................9-

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Tail light installation ..............................................................................................9-

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High mount stop lamp removal ............................................................................9-

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High mount stop lamp disassembly .....................................................................9-

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High mount stop lamp installation .......................................................................9-

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Chapter 10    Troubleshooting

 

 

Troubleshooting Instructions P art 1............................................................................ 10-

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Check procedures..................................................................................................10-

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Index for check procedures .................................................................................10-

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Check Procedure 1-- Battery/ voltage check ....................................................10-

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Check Procedure 2--Accelerato r signal voltage...............................................10-

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Check Procedure 3-- Motor voltage at A1 and A2 ..........................................10-

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Check Procedure 4 - TOW/RUN switch ...........................................................10-

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Check Procedure 5

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Battery voltage ................................................................10-

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Check Procedure 6

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Circuit check for key switch and accelerator pedal switch10-

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Check Procedure 8 

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 vo ltage at the red wire jack o f charger receptacle......10-

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Check Procedure 9

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Motor speed sensor.........................................................10-

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Check Procedure 10

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forward/reverse gear switch ........................................10-

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Check Procedure 11

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Reverse buzzer ..............................................................10-

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Check Procedure 12  -- Battery discharge meter...............................................10-

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Check Procedure 13 -- High mo unt stop lamp ..................................................10-

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Check Procedure 14  - wiper................................................................................10-

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Check Procedure 15

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flashing light..................................................................10-

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Troubleshoo ting Instructions Part 2 .......................................................................................................................10-14  

 

CHAPTER 11    BATTERY AND CHARGER 

B

ATTERY

................................................................................................................................................................................11 -1  

Overview.......................................................................................................................................................................11 -1  

Co mmon misconceptions about battery ...................................................................................................................11 -2  

Battery replacement.....................................................................................................................................................11 -3  

Battery maintenance....................................................................................................................................................11 -4  

P reventative maintenance ...........................................................................................................................................11 -4  

Self discharge ...............................................................................................................................................................11 -5  

Electrolyte liquid level................................................................................................................................................11 -5  

Mineral co ntent ............................................................................................................................................................11 -6  

Vibration damage.........................................................................................................................................................11 -6  

Battery charging...........................................................................................................................................................11 -6  

Deep discharge.............................................................................................................................................................11 -7  

Summary of Contents for E-MERGE 2007

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: ...1 E MERGE Maintenance Manual Revision as of August 9 2007 ...

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: ... Regular Inspection and Adjustment Regular Maintenance 2 Error Bookmark not defined Periodic Lubrication Plan 2 Error Bookmark not defined Braking Inspection 2 Error Bookmark not defined Inspection of Parking Brake 2 Error Bookmark not defined Inspection of Brake Drum and Brake Shoe 2 Error Bookmark not defined Inspection of the Accelerator Pedal 2 Error Bookmark not defined Inspection of the Stee...

Page 5: ...not defined Remove 4 Error Bookmark not defined Install 4 Error Bookmark not defined Removal of the Dashboard 4 Error Bookmark not defined Remove 4 Error Bookmark not defined Install 4 Error Bookmark not defined Removal of the Rear Cover 4 Error Bookmark not defined Remove 4 Error Bookmark not defined Installation 4 Error Bookmark not defined Rear cover 4 Error Bookmark not defined Chapter 5 Front...

Page 6: ...or Bookmark not defined Removal of forward reverse gear switch 9 Error Bookmark not defined Installation of forward reverse gear switch 9 Error Bookmark not defined Battery discharge meter removal 9 Error Bookmark not defined Battery discharge meter installation 9 Error Bookmark not defined Horn removal 9 Error Bookmark not defined Horn installation 9 Error Bookmark not defined Combination switch ...

Page 7: ...dure 4 TOW RUN switch 10 Error Bookmark not defined Check Procedure 5 Battery voltage 10 Error Bookmark not defined Check Procedure 6 Circuit check for key switch and accelerator pedal switch10 Error Bookmark not defined Check Procedure 8 voltage at the red wire jack of charger receptacle 10 Error Bookmark not defined Check Procedure 9 Motor speed sensor 10 Error Bookmark not defined Check Procedu...

Page 8: ...the charger 11 18 Maintenance of the battery charger 11 18 Troubleshooting 11 19 Diode test procedure 11 19 Procedures for component replacement 11 19 Charger trouble shooting procedure 11 20 Chapter 12 Electric Motor Overview 12 Error Bookmark not defined Exterior inspection of the electric motor 12 Error Bookmark not defined Check Procedure 1 internal short circuit 12 Error Bookmark not defined ...

Page 9: ...rk not defined Specifications for the electric motor 12 Error Bookmark not defined Assembly of the electric motor 12 Error Bookmark not defined Mounting of the electric motor 12 Error Bookmark not defined Speed sensor of the electric motor 12 Error Bookmark not defined Inspection of the speed sensor of the electric motor 12 Error Bookmark not defined Removal of the speed sensor 12 Error Bookmark n...

Page 10: ...gnition 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 should be used for taking this measurement Do not connect the wire with the negative electrode first Connect it at last Do not charge the battery while it is refrigerated The battery should be unfrozen before i...

Page 11: ... and the working area The place where the battery is charged should be a space where it is kept in good ventilation While maintaining or working beside the battery the operator should wear a full face mask and rubber gloves Batteries are toxic and contain acid fluid that may cause serious burns if the fluid should contact the skin Anti acid measures Exterior Flush the area where acid is spilled wi...

Page 12: ...ectric vehicle that may affect its stability or maneuverability or any speed increase beyond the maximum speed specified in the manufacturer s specifications may result in death and serious personal injury Refer to the user s manual for the corresponding positions labeled on the electric vehicle of all WARNING marks and ensure that they are in place and easily visible During the maintenance of ele...

Page 13: ...g 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: ...nd 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 vehicle the lifting...

Page 15: ...ectric 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 gravity of the electrolyte of the electrolyte Cautions Washing and Cleaning Before the maintenance thoroughly clean the body and exterior of the components During the cleaning care should be taken to p...

Page 16: ... oil seals on which the manufacturer s mark and number are present the mark and number should face outwards for easy identification All the bearing and oil seals once removed must be replaced with new ones To apply the oil seal cover a thin layer of light lithium grease over the oil seal While mounting the bearing the lubricants should be fully applied Recommendations on Disassembly and Assembly F...

Page 17: ...and inspect the retaining screws and terminals for tightness S S S S S Inspect the brake pedal for free travel and make adjustments when necessary C CA CA CA CA Inspect the operation of the steering wheel C C C C C Inspect the tire pressure and the tire recession and tread for damage C CA CA CA CA Inspect the body and chassis for damage C C C C C Inspect all the bolts nuts and screws for tightness...

Page 18: ...ust the gear box when necessary CA Periodic Lubrication Plan Periodic lubrication plan Normal intervals Maintenance Lubricated points Recommend lubricating oil Brake pedal shaft 1 3 Lithium based grease Parking brake 2 3 Lithium based grease Accelerator pivot bar foot 3 3 Lithium based grease Charger receptacle 4 NYE760G Front suspension 5 3 Lithium based grease Front stub axle 7 Lithium based gre...

Page 19: ...18 ...

Page 20: ... wheel brake tong 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 wearing value 1 0 mm 0 04 in Damaged defective one is to be replaced 3 Measure Free play of the brake pedal Push against the pedal by hand slightly and measure the ...

Page 21: ...nspection of Parking Brake 1 Turn the master 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 play 15mm 0 591in In case of non compliance with the standard adjustment is to be made ...

Page 22: ...ear wheels 4 Loosen the brake drum and knock slightly on the drum with mallet 5 Inspect Internal surface of the brake drum Oil Fully clean until no oil is found Scrape Rub lightly with the abrasive cloth Brake wheel cylinder Where the upstream assembly is in normal working condition step on the brake pedal In case the brake wheel cylinder cannot open the brake shoe or oil leakage is found the brak...

Page 23: ... 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 value 1 75mm 0 07in ...

Page 24: ...rake drum and shoe block 10 Install Wheel nuts Tightening torque 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: ...ons 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 2 Tighten Nuts of steering wheel Tightening torque 50Nm 36 9ft 1b Bolts of un...

Page 26: ...ove the locknuts support the connecting link with a 16mm spanner 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 tie rod and steering ball joint ...

Page 27: ...he 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 the flat surface 2 Push the vehicle directly forward for about 20 steps to stabilize the suspension gear NOTICE Do not pull back the vehicle or step on the brake pedal as it will result in the change of toe in 3 Measure Toe in No load 5 8mm 0 20 0 32in Full l...

Page 28: ...e in decrease Tighten the locknuts on the drag link ball joints Tightening torque 40Nm 29 5ft 1b Inspection of Tires and Wheel Rim 1 Measure Air pressure In case of non compliance with the standard adjustment is to be made Tire pressure front and rear tires 200 220kPa Inspect Tire surface In case of any abrasion damage scrape or inset the tire is to be replaced Wheel rim In case of any damage or d...

Page 29: ...e 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 replaced 5 Lightly swing the half shaft of the rear axle In case that the free gap is too large the bearing is to be replaced NOTICE We do not recommend the replacement of bearing and bearing sleeve as an individual part...

Page 30: ...ng bolts of the rear shock damper Tightening torque 63Nm 46 5ft1b Inspection of the Seat Belt 1 Binding Force of the Seat Belt Pull down the seat belt swiftly and the retractor should respond quickly to 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 ...

Page 31: ...e 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 Chapter 3 Canopy ...

Page 32: ...3 Canopy Install Canopy In the reverse order of the removal procedures Tightening torque 9 Nm 6 6ft1b Removal of Canopy Rods Remove 1 Fixing bolt on the rear pillar 1 2 Fixing bolt on the center pillar 2 E 4 3 Install slip bolt 3 4 Canopy rod 4 5 Fixing bolt of front canopy rod 5 6 Front canopy rod 6 ...

Page 33: ...rque for 1 2 5 23Nm 17 0 ft1b Removal of the Pillar Remove 1 Fixing bolt of backrest bracket 1 2 Backrest bracket 3 Fixing bolt on the rear pillar 2 4 Fixing bolt on the rear pillar branch 3 5 Rear pillar 6 Rear pillar branch 7 Fixing bolt on the center pillar connector 4 E 4 8 Center pillar connector 9 Fixing bolt on the center pillar 5 E 4 10 Center pillar ...

Page 34: ...33 Install Pillar In the reverse order of the removal procedures 1 Tightening torque 9 Nm 6 6 ft1b Tightening torque for 2 4 5 63 Nm 46 5 ft1b 3 Tightening torque 23 Nm 17 0 ft1b ...

Page 35: ...ear 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 63 Nm 46 5 ft 1b Install Rear bumper Rear bumper bracket ...

Page 36: ...35 Tightening torque 63 Nm 46 5 ft 1b Install Clamping nut Rear tray Rear box cover ...

Page 37: ...on seat cushion bottom plate Seat cushion Bottom plate of seat cushion 2 E 2 Removal of the Backrest Remove Bolt Backrest 3 2 2 Series Backrest Removal Remove Bolt 1 Rear seat backrest 2 Bolt 3 Rear seat backrest bracket 4 Backrest 5 Install Front seat backrest Tightening the torque of bolt 23 Nm 17 0 ft 1b Rear seat backrest 2 2 series Tightening the torque of bolt 23 Nm 17 0 ft 1b ...

Page 38: ...37 Seat cushion Bottom plate of seat cushion Bolts on seat cushion bottom plate Handrail bracket Handrail bracket fixing bolt Tightening torque 23 Nm 17 0 ft 1b ...

Page 39: ...strument panel Rubber nail on the upper dashboard Fixing nuts on the lower dashboard Tightening torque 9 Nm 6 6 ft 1b Fixing bolt on the lower dashboard 2 Remove Front cover nuts Tightening torque 9 Nm 6 6 ft 1b Front cover bolts 3 Remove Front cover Install In the reverse order of the removal procedures ...

Page 40: ...ixing 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 Disengage the clasp and remove the baffle 7 Remove Edg...

Page 41: ...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 4 Remove Fixing bolts of lower hinge Tightening torque 7 Nm 5 2 ft 1b Hinge Rear cover bolt Tightening torque ...

Page 42: ...41 7 Nm 5 2 ft 1b 5 Remove Rubber nail of rear cover plate Rear cover plate Rear cover Installation In the reverse order of the removal procedures ...

Page 43: ... 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 Chapter 5 Front Axle ...

Page 44: ... lug shaft 10 Hub coupling 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 stub axle 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 cradle 28 Air valve 29 Upper lug 30 Bolt ...

Page 45: ...t wheel nut Front wheel 6 Inspect The operation of wheel bearing Rotate the hub coupling by hand In case of unsmooth operation the bearing is to be replaced with new one 7 Inspect Free gap of wheel bearing Swing the hub back and forth In case the free gap is too large the slotted nut is to be tightened In case the clearance is still too large the bearing is to be replaced with new one 8 Remove Dus...

Page 46: ...que 23 Nm 17 0 ft 1b Brake tongs 11 Remove Hub coupling of front wheel Knock at the coupling with a soft hammer 12 Remove Brake disc bolt Tightening torque 23 Nm 17 0 ft 1b Brake disc Standard thickness of brake disc 4 mm 0 16 in Maximum wearing thickness 1 mm 0 04 in ...

Page 47: ...ect Stub axle free gap Swing the stub axle In case the free gap is fairly large the inside spacer and bush of the stub axle are to be replaced NOTICE The inside space and bush should be replaced together 15 Remove Removal of Drag Link Ball Joint Please refer to Chapter 2 Removal of Drag Link Ball Joint Split pin Pivot slotted nut Stub axle lug Stub axle ...

Page 48: ... free gap is fairly large the inside spacer and nylon bush of the cradle are to be replaced NOTICE The inside space and nylon bush of the cradle should be replaced together 17 Remove Front shock damper bolt Tightening torque 63 Nm 46 5 ft 1b Front shock damper Cradle bolt Tightening torque 60 Nm 44 3 ft 1b ...

Page 49: ...oil seal is to be replaced Procedures for the replacement of hub coupling bearing and oil seal cover Clean the interior of hub coupling Remove the oil seal and bearing with the special bearing puller Install new oil seal cover and bearing in the installation procedures mentioned above NOTICE Use a hold down clamp that is consistent with the diameter of bearing and inside loop of oil seal cover Cau...

Page 50: ...eplaced 7 Cradle In case of damage deformation the cradle is to be replaced Install In the reverse order of the removal procedures Note the following 1 WARNING The split pin once removed must be replaced with new one 2 Install Front wheel Wheel nut of front wheel Tightening torque 90 Nm 66 4 ft 1b ...

Page 51: ...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 Bolt 37...

Page 52: ...ting 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 wheel Rear wheel...

Page 53: ...m fixing nut Tightening torque 63 Nm 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 coupling with hand and in case of unsteady rotation or abrasion the half axle assembly is to be replaced ...

Page 54: ... spring and shoe plate locating dowel 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 55 Nm 40 6 ft 1b Half axle outer tube Inspect and test 1 Measure Inside diameter of brake drum ...

Page 55: ...E We do not recommend the replacement of bearing and bearing sleeve as an individual part During the operation the quality of fit between half shaft and bearing or bearing sleeve may deteriorate In this case we usually recommend the replacement of a new rear axle half shaft assembly In addition due to the complex internal structure of the brake we recommend that the maintenance personnel replace o...

Page 56: ...e Bolt 6 Spring Nut 8 Tightening torque 23Nm 17 0 ft 1b 3 Install Half axle outer tube of rear axle Bolt 4 Tightening torque 55 Nm 40 6 ft 1b 4 Install Brake shoe plate Upper tension spring Lower tension spring 11 Locating dowel Clipping spring Procedures for the installation of brake shoe plate Apply the high temperature grease over the two ends of the metal support of the brake shoe plate ...

Page 57: ...te surface is not tainted with grease 5 Install Brake drum Rear wheel assembly Wheel nut of rear wheel Tightening torque 90 Nm 66 4 ft 1b 6 Install Bleeding bolt Tightening torque 70 Nm 51 6ft 1b Remarks Apply 1100mL lubricating oil GL 4 or GL 5 to the rear axle 7 Install Oil filler screw plug ...

Page 58: ... Oil filler plug 7 Ring gear 8 Differential gear 9 Bearing pressing block10 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 59: ...erential 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 60: ...ial gear assembly 4 Remove Sealing rubber cover both ends 5 Remove Oil seal 1 Clip spring 2 Bearing fixing bush 3 Bearing 4 Input shaft 5 6 Remove Clip spring from countershaft gear Bearing 6 Gear bush 7 Countershaft 8 Countershaft gear 9 ...

Page 61: ...t gear on the other side Inspection 1 Inspect Ring gear 1 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 54 Nm 39 8ft 1b ...

Page 62: ...rface 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 63Nm 46 5ft 1b 2 Apply Oil Recommended oil GL 4 or GL 5 gear oil Oil volume 1100mL ...

Page 63: ...der 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 Grease cup 31 Clamp 32 Tee joint ...

Page 64: ...rake pedal fixing bolt Brake pedal fixing nut 9 Tightening torque 49 Nm 36 1 ft 1b Brake pedal 2 Fixing bolt of brake master cylinder 3 Fixing nut of brake master cylinder 10 Tightening torque 65Nm 47 9 ft 1b Brake master cylinder 4 Brake pipe 5 Tee joint 6 Inspect Brake master cylinder 4 Brake pipe 5 Tee joint 6 In case of oil leakage deformation damage replacement is to be made Parking brake han...

Page 65: ...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 66: ...65 Accelerator pedal 1 Accelerator pedal 2 Accelerator 3 Accelerator bracket 4 Pivot 5 Split pin 6 Pin axle 7 Washer 8 Split pin ...

Page 67: ...int Spline housing 16 Universal joint Spline shaft 17 Universal joint dust boot 18 Bolt 19 Spring washer 20 Flat washer 21 Steering gear enclosure 22 Bolt 23 Outer clasp 24 Tape 25 Dust boot 26 Adjusting nut 27 Adjusting cover 28 Compression spring 29 Pressing block 30 Oil seal 31 Pinion shaft 32 Inner clasp 33 Outer clasp 34 Dust cover 35 Bearing 36 Bush 37 Drawbar of steering gear 38 Rack 39 Thr...

Page 68: ... wheel nuts Steering wheel 5 Remove Dashboard Please refer to Chapter 4 Removal of the Dashboard Disconnect the combination switch connecting line Combination switch harness jacket Bolt Combination switch 6 Remove Upper fixing bolt of the steering column pressing block Tightening torque 10 Nm 7 4 ft 1b Lower fixing nut of steering column pressing block Tightening torque 63 Nm 46 5 ft 1b Upper fixi...

Page 69: ...gs 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 23 Nm 18 4 ft 1b Universal joint assembly Fixing bolt on the steering gear Tightening torque 40 Nm 29 5 ft 1b Steering gear Disassembly of the Steering Gear 1 Disassemble Drag link ball joint of the steering gear Secure the drawbar of...

Page 70: ...ICE The tape once removed will be a destroyed and should be replaced with a new one 2 Disassemble Inner clasp Large flat washer Dust boot of steering gear 3 Disassemble Thrust washer Drawbar of steering gear ...

Page 71: ...g 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 unsmooth operation the bearing should be replaced 6 Disassembl...

Page 72: ... 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 Whether the ball joint has the following symptom Unsmooth operation 1 Over loose free gap 2 Bending or deformation 3 Damage of dust boot 4 NOTICE In case of any of the above condition replace with a new ball join...

Page 73: ...of system parts Adjust the tightening torque of the cover 1 5 2 Nm 1 1ft 1b 1 48ft 1b NOTICE The steering gear should have no clamping stagnation when the left and right racks turn to the final positions When they return to the middle position the free gap of the steering wheel should be 45mm or else the steering gear assembly must be replaced Adjust the tightening torque of locknut 39 Nm 28 8ft 1...

Page 74: ... switch until the plug in package connecting the key switch wire to the main cable appears disengage the plug in package of the key switch wire from that of the main cable 5 Hold the key switch and remove the switch lock nut from outboard of instrument panel 6 Check Refer to Check Procedure 6 Circuit check for key switch and accelerator pedal switch of Chapter 10 replace the part in case of any in...

Page 75: ...The red black yellow and blue white wires must be connected correctly at relevant positions on the gear switch Battery discharge meter removal Check Refer to Check Procedure 12 Battery discharge meter in Chapter 10 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 Remove the middle electrical r...

Page 76: ... 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 1 and remove the horn 6 Check the horn for continuity Replace the part in case of un continuity Horn installation Return to disassembling steps NOTE The horn wire must be connected correctly The tightening torque of the ...

Page 77: ...bination switch 5 Remove the set bolt 2 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 1 of the combination switch and remove the combination switch 3 8 Turn the switch lever and check the relevant gears for continuity replace the part in case of un continuity Combination switch installation Back to disasse...

Page 78: ...efer 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 63Nm 46 5ft1b 8 Remove the safety belt buckle 9 Disconnect all wires and multi wire connectors from the controller Control circuit ...

Page 79: ...d 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 Forward Reverse gear switch is on REVERSE position the reverse buzzer should sound a warning tone When Forward Reverse gear switch is on NEUTRAL position make sure the electric vehicle remains ...

Page 80: ...r contact and wear and replace the part if necessary Charger receptacle installation Back to the removal steps Battery removal 1 Take out the key from the key switch 2 Apply the parking brake 3 Remove the seat pad assembly 4 Disconnect the battery cable according to the directions Please refer to Chapter 1 Protection for Electrical Safety 5 Remove the nut on the battery hold down 6 Remove the batt...

Page 81: ...the key switch 2 Apply the parking brake 3 Remove the seat pad assembly 4 Turn Tow Run switch to TOW Please refer to Chapter 1 Protection for Electrical Safety 5 Disconnect the wire plug in package of DC converter 6 Remove the four set bolts 7 Remove the DC converter DC converter installation Back to the removal steps ...

Page 82: ...over 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 DC changeover contactor coil Replace the part in case of u...

Page 83: ... 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 7 Wrap the motor at the mid position with a wide band lift the motor carefully and move it to the left horizontally then place it on the ground gently Low resistor High resistance Select Reverse bias Select F...

Page 84: ...probe to the motor case 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 ...

Page 85: ... the red probe to F1 and connect the black probe to F2 The multi meter should show connection In case of above reading errors have the motor repaired by a professional Motor installation Back to the removal steps NOTE Match the marking line during motor installation ...

Page 86: ...th 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 bulb 9 Check the bulbs of the headlight and the turn signal lamp for continuity and replace the part in case of un continuity H...

Page 87: ... 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 switch to TOW Please refer to Chapter 1 Protection for Electrical Safety 4 Remove the screw with a screw...

Page 88: ...b 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 wiper motor ...

Page 89: ...tact 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 can...

Page 90: ...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 signal lamp bulb Re...

Page 91: ...nged 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 switch 11 Backing b...

Page 92: ...an 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 connect the black probe of a multimeter set at 200V DC to motor term...

Page 93: ...the voltage is lower than 41V If the battery voltage is lower than 41V it indicates the battery is completely discharged or faulty 6 Record the voltage reading of the battery pack in under voltage state allows a more accurate diagnosis on battery condition When the discharger is started it will result in battery pack under voltage repeated operations are helpful to determine the failure of one or ...

Page 94: ...pressed 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 the pedal switch circuit in the following procedures 9 3 1 Use a multimeter set at 200V DC connect the black probe to the negative binding post of Battery 6 and connect the red probe to the pedal switch output wire Wire 1 Tur...

Page 95: ...h sends a 48V signal to the controller through Pin 5 1 Use a multimeter set at 200V DC insert the red probe of the multimeter into Pin 4 black yellow wire Refer 8 wire connector of controller plug Function Pin 1 red wire Battery positive electrode 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...

Page 96: ...ld display a voltage of 48V 8 Turn Forward Reverse switch to REVERSE the multimeter should display a full battery voltage about 48V 9 If another reading is displayed the following items must be checked Continuity of wires in harness Whether Forward Reverse switch operates normally Refer to Check Procedure 10 Forward Reverse gear switch Check whether Tow Run switch operates normally Refer to Check ...

Page 97: ...ry pack Δ Note Never insert the complete probe into the 8 wire plugfor fear of poor contact 2 When Tow Run switch is turned on RUN and Forward Reverse switch is on NEUTRAL the multimeter should display a 0V DC voltage 3 Depress the accelerator pedal the multimeter should display the full battery voltage about 48V 4 If multimeter voltage does not change the following items must be checked Continuit...

Page 98: ... the red probe to the terminal of Wire 14 of the 3 wire connector on the motor speed sensor The voltage reading should be approximately 4 60 5 00V 5 2 If the reading is 0V check the continuity of Wire 14 of 3 wire connector which connects the controller and the motor speed sensor If the continuity is ok replace the controller 5 3 If the reading is lower than 3 50V check the wire and plug for conti...

Page 99: ...ected use a multimeter set at 200V DC connect the black probe to the negative binding post of Battery 6 and connect the red probe to the disconnected red terminal of the reverse buzzer The voltage reading should be approximately 48V the battery is fully charged 7 If the voltage reading is correct go to Step 12 8 If the reading is 0 check the continuity of the red wire and Tow Run switch Refer to C...

Page 100: ...eplace 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 Check the brake switch for normal operation 4 If everything is ok and the measured voltage is still 0 replace the main cable Check Procedure 14 wiper Please refer to Chapter 1 Protection for Electrical Safety With Tow Run switch on RUN and key switch...

Page 101: ...s 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 there is no 12V output replace the main cable 4 If the above checks are satisfactory ie there is a 12V output connect the flashing light interface to the main cable to check the flashing light for normal operation replace the flashing light if it d...

Page 102: ...tom The controller does not operate Possible causes Start switch circuit failure Check that the start switch is closed when the accelerator pedal is depressed Check the start switch wiring for open circuit and loose connection Accelerator pedal failure Check accelerator pedal for normal operation Troubleshooting diagram L P1 P2 P3 P5 P11 P10 P15 P14 P16 P7 P9 P8 P6 P18 P19 P20 P21 P13 P22 P23 Star...

Page 103: ...rse switch is turned on The state code should disappear when the direction switch is closed or accelerator pedal is released Direction switch failure Check that the Forward Reverse switch is closed during direction selection Open circuit between direction switch and battery positive electrode or P4 P5 Check all controller wirings and connections in troubleshooting diagram Troubleshooting diagram L...

Page 104: ...ive Symptom The controller does not operate Possible causes Improperly adjusted input power or faulty accelerator The input voltage at P7 should be lower than 0 9V Adjust or replace accelerator to ensure the voltage at P7 is lower than 0 9V Troubleshooting diagram L P1 P2 P3 P5 P11 P10 P15 P14 P16 P7 P9 P8 P6 P18 P19 P20 P21 P13 P22 P23 Start sw itch Key switch Forw ard R everse Buzzer IrDa R S232...

Page 105: ...ition Short circuit between battery positive electrode and P4 or and P5 Disconnect the wire between P4 and P5 check the wiring on positive electrode of direction switch for short circuit Controller failure Disconnect the wire and measure the voltage between P4 and P5 The voltage should be lower than 50 of battery voltage otherwise replace the controller Troubleshooting diagram L P1 P2 P3 P5 P11 P1...

Page 106: ...attery voltage Adjust or replace accelerator pedal to ensure the voltage at P3 is lower than 50 of battery voltage before the start switch is closed Short circuit between battery positive electrode and P3 Check the continuity of the wire between the two points Controller failure Disconnect the wire to P3 Measure the voltage between P3 and the negative electrode The voltage should be 0 Otherwise re...

Page 107: ...ction action Draught regulator circuit active Symptom The controller does not operate Possible causes Battery is discharged Check that the battery voltage is higher than 34V Charge the battery if necessary Battery failure Check the voltage of each battery cell battery cell voltage should be greater than 1 95 volts Replace or repair the battery Check the min battery voltage at P1 and negative elect...

Page 108: ...ectrode Troubleshooting diagram FU3 Charger switch Key switch Negative electrode Draught state code State description Cause of state indication signal 21 Accelerator input voltage is high This state code is displayed when the accelerator input voltage at P7 is greater than 4 5V Memory No Correction action Draught regulator circuit active Symptom The controller does not operate Possible causes Impr...

Page 109: ...r Controller failure Replace controller No diagram for this state code Draught state code State description Cause of state indication signal 24 Motor field current is high when the key switch is opened This state code is displayed in case of a high current consumption in motor field when starting Memory No Correction action Draught regulator circuit active Symptom The controller does not operate P...

Page 110: ...ontroller does not operate Possible causes Battery discharged Check battery ensure the correct charging state The voltage may be lower than 15V under load Loose connection at P1 Make sure the wire is connected firmly at P1 Short circuit between Pin 15 and the negative electrode of the battery Check the continuity and connection of the wire between the two points Controller failure Replace controll...

Page 111: ...ture protection voltage is lower than 1V it is generally presented by controller failure GE Sentry applicable for Windows software can be used to monitor controller operation and display values greater than 84 corresponding to 1 65V and activate the state code Troubleshooting diagram Start Sentry The monitor is active ZX controller state monitor Controller model State Function Value Reading Minimu...

Page 112: ...ftware can be used to monitor controller operation and display values greater than 84 corresponding to 2 7V and activate the state code Troubleshooting diagram Start Sentry The monitoris active ZX controller state m onitor Controller model State Function Value Reading Minim um Maximum Unit Acce lera tor pedal volta ge V Motor current A N A Battery voltage V T2 Voltage V Make time Make time Overtem...

Page 113: ...age V Motor current A N A Battery voltage V T2 Voltage V Make tim e Make time Overtempera tur e protec tion Battery power level Power level F1 current A F2 current A N A 12V bus V Switch register Reverse off Forward off Reset off Start on Key switch Active Speed limit Hourm eter Inactive Start Diagram Default Value Close Draught state code State description Cause of state indication signal 44 The ...

Page 114: ... signal 46 Voltage at A2 look forward is tested to be lower than 12 5 of battery voltage This state code is displayed if the voltage at A2 is lower than 12 5 of battery voltage when the controller is on neutral and the start switch or direction is not selected and Im is greater than 52A Memory Yes Correction action Draught regulator circuit active Symptom The circuit contactor does not pick up Pos...

Page 115: ...te code Draught state code State description Cause of state indication signal 51 Capacitor voltage remains low before the circuit contactor is closed This state code is displayed if the capacitor voltage is lower than 85 of battery voltage when the start switch is turned on initially Memory No Correction action Draught regulator circuit active Symptom When the capacitor is not pre charged the circ...

Page 116: ... power cords between motor and controller are connected firmly Check that the power supply fuse is in good condition and replace it if necessary The circuit contactor springs back or picks up incompletely Controller failure Replace controller Troubleshooting diagram No diagram for this state code Draught state code State description Cause of state indication signal 64 This state code is displayed ...

Page 117: ... Exciting current exceeding the limit of field effect transistor This state code is displayed when the field effect transistor is turned off and the start switch must be repeatedly operated to restart the controller Memory Yes Correction action Draught regulator circuit active Symptom The controller does not operate or no power is available when starting Open circuit of circuit contactor Possible ...

Page 118: ...dly to remove trouble Turn off the start switch for 20s then turn it on Circuit Positive electrode Powersupply wiring to controller Negative electrode Draught state code State description Cause of state indication signal 77 High capacitor 1C voltage when speeding up or depressing regenerative brake This state code will be displayed when the voltage at 1C is higher than 79V during operation Memory ...

Page 119: ... holes to allow the passage of charged ions through positive and negative plates while preventing the contact of the plates Two different metals that are immersed into one acid can generate the electric current In the deep cycle battery the negative plate contains plum bum Pb and the positive plate contains lead dioxide These plates are immersed in the sulfuric acid solution H2SO4 see Fig 11 1 Dur...

Page 120: ...harge These are new batteries Therefore they can supply power all day long The new battery cannot reach its full capacity until being used and charged for twenty to fifty times Please refer to premature excessive discharge Mineral content Our batteries can use tap water Your tap water may be OK but inspection before hand is required Please refer to mineral content Self discharge The dirt and rust ...

Page 121: ... The inclination of the battery should not exceed 45 when being lifted carried or mounted The battery acid may result in serious personal injury to the skin or eyes and may also damage the clothes 1 Before removing the battery please note the orientation of the battery and connecting line Disconnect the battery cable according to the instructions Please refer to Chapter 1 Protection for Electrical...

Page 122: ...of the battery compartment is balanced Battery maintenance Preventative maintenance To maintain the battery in good working order please take the following procedures regularly 1 The rust and dirt on or around the battery should be cleaned immediately The terminal joints should be cleaned and secured Replace the aged or worn wires Apply the terminal protection oil to all the connecting terminals a...

Page 123: ...rear body of the electric vehicle Battery acid may result in irremediable defect and should be cleaned up immediately Fig 11 6 Liquid level of battery solution Water is filled only when the liquid level of electrolyte is lower than the height of positive and negative plates In case the liquid level of electrolyte is lower than the height of positive and negative plates please fill enough water to ...

Page 124: ...e too tight so as to prevent the battery enclosure from being fractured or bent This will result in leakage and further to the dry up of the battery compartment or short circuit Please refer to Chapter 1 Protection for Electrical Safety Battery charging The charger provided for the E merge electric vehicle has brought a solution to the common problem relating to the battery charging The charger ca...

Page 125: ...r trips the fuse is burnt at night or the charger fails to reach the required starting velocity when it charges the normal battery the problem may lie with the AC power line When all charges are open the power supply line of the storage facility of the electric vehicle can supply sufficient voltage and current for each charger In case it fails to do so please consult with the local power company o...

Page 126: ...efects In case no problem is identified All the readings are lower than In case the reading of any single battery is lower than 9 3V and its All the readings are higher than It may be used battery Carry out Hydrometer test Replace the battery that the specific gravity of two batteries exceeds 50 The whole set of battery of which the specific gravity reading is lower than 1 250 is usually underchar...

Page 127: ...h 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 terminals of all batteries and attach the black probe to the negative terminals of all batteries Take down the reading The charged battery of the battery pack should...

Page 128: ...ydrometer to return back to the battery compartment Replace the air bleeder cover 7 Repeat Step 2 6 to all battery compartments Calibration of hydrometer Most of the hydrometers are calibrated and can perform precise measurement under 80 26 7 The above observed readings should be corrected according to the temperature Every increase of 10 5 6 over 80 26 7 should result in the addition of 0 004 to ...

Page 129: ...y 2 69 5 80 F 26 7 C 000 1 250 0 1 250 1 255 0 1 255 1 230 0 1 230 1 250 0 1 250 Light current battery 3 additional charge 38 2 100 F 37 8 C 008 1 200 008 1 208 1 180 008 1 188 1 170 008 1 178 1 180 008 1 188 Discharged battery recharge and re inspection 22 4 80 F 26 7 C 000 1 240 0 1 240 1 245 0 1 245 Buoy doesn t float 1 250 0 1 250 Rejected battery 3 replacement Discharge test In case no proble...

Page 130: ... 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 When the shut off voltage is reached the tester will shut off automatically Fig 11 9 Battery discharge test Discharge test result presentation 1 In case the discharge time is not less than 60 minutes the problem is not with battery 2 In case the discharge...

Page 131: ...V 9 80 V 10 16V 10 56V 10 61V As battery No 3 No 1 and No 4 are suspected to have problems hydrometer inspections are conducted on all batteries Hydrometer inspection result Battery number Battery compartment number 1 2 3 4 5 6 Battery 1 positive terminal 1 200 1 265 1 300 1 250 1 280 1 260 Battery 2 1 285 1 275 1 290 1 270 1 295 1 265 Battery 3 negative terminal 1 265 1 270 1 275 1 265 1 280 1 27...

Page 132: ...ry 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 storage 4 Store the battery in shady and cool places The lower the temperature where the battery is stored is the less electricity quantity the battery self discharges The electric ...

Page 133: ...ded 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 below and surrounding the charger In case the charger is used outdoors rain and sun shields must be provided see Fig 11 10 The charger needs a special circuit For proper circuit protection method please refer to ...

Page 134: ...rger The battery charger will respond to abnormal conditions In case the charger is disconnected with the vehicle during the charge cycle it will shut off immediately In case the AC supply is disconnected when the power supply is resumed the charge cycle will continue till the remaining cycle is completed In case the storage battery is fully charged in a very short period less than 2 hours the cha...

Page 135: ...nance the charger requires is the periodic cleaning 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 Troub...

Page 136: ...nnect 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 the given one the diode is broken It can be replaced as required Procedures for component replacement To replace the parts install them in the procedures just reverse to the removal procedures Any disconnected wire should be given ...

Page 137: ...ire 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 housi...

Page 138: ... 17 lester full automatic controllable silicon charger wiring diagram Low Resistance High Resistance Select Select S Reverse bias Forward bias DVOM is for reference only For detailed instructions please refer to the manufacturer s user manual ...

Page 139: ...h the 100 LED 6 When Models 912 xx0x 100 LED or Models 912 xx1x single LED is continuously GREEN the batteries are completely charged The charger may now be unplugged from AC power always pull on plug and not cord to reduce risk of damage to the cord If left plugged in the charger will automatically restart a complete chare cycle if the battery pack voltage drops below a minimum voltage or 30 days...

Page 140: ...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 operation the charger must be installed s...

Page 141: ...ded with algorithms for batteries as detailed in Table 1 If your specific battery model is not listed please contact Delta Q Each time AC power is applied with the battery pack NOT connected the charger enters an algorithm select display mode for approximately 11 second During this time the current Algorithm is indicated on the 80 LED Models 912 xx0x or on the single LED Models 912 xx1x A single d...

Page 142: ...he output relay is heard to click 10 seconds algorithm is now in permanent memory c Remove AC power from the charger and reconnect the charger positive connector to the battery pack It is highly recommended to check a newly changed algorithm by repeating step4 above Chapter 12 Electric Motor Overview ...

Page 143: ...be 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 by professionals Please refer to Chapter 9 Removal of Motor 3 1 The wrong readings on A1 or A2 terminals may imply three kinds of problems A1 or A2 grounding grounding of wires in the electric br...

Page 144: ...tor 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 contact of terminal bond The electric motor should be removed from the vehicle and be repaired by professionals Please refer to Chapter 9 Removal of Motor Fig 12 1 Inspection of the short ...

Page 145: ...e brush terminals A1 and A2 13 to indicate their positions in the end shield 10 Then unscrew the nut 6 spring washer 7 small washer 3 and large washer 5 see Fig 12 7 Insert the terminal into the interior of the stator enclosure through the enclosure wall 7 Carefully remove the brush set and terminals from the end shield 8 To remove the brush spring 14 from the gear pry out the elongation portion o...

Page 146: ...s 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 driving axle may be damaged Armature earth test WARNING It is strictly prohibited to immerse the armature into any solvent NOTE Before testing the armatur...

Page 147: ...lace the electric motor or the stator enclosure component Motor element 1 Inspect the insulator 4 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 changes amber or blue due to being heated Replace the spring of which the elasticity is smaller than...

Page 148: ...l 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 the bearing 15 and pull the bearing from the armature shaft Support the shaft so that it will not fall off when the bearing is removed see Fig 12 8 Reject the bearing Mounting of the bearing Press the new bearing 15 against the a...

Page 149: ...f 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 150: ...ecifications 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 151: ...erminal 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 Secure the brush tran...

Page 152: ...e 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 In assembly of th...

Page 153: ... 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 grease should be ...

Page 154: ... 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 figure see Fig 12 15 C...

Page 155: ...res 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 4Nm Apply the antirust oil on all connecting terminals to minimize future corrosion 7 Set the Tow Run switch at the RUN ...

Page 156: ...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 4Nm see Fig 12 16 2 As shown in the figure align the speed sensor 21 and secure it with the screwdriver 3 Plug the three wire connector 22 onto the harness of the electric ...

Page 157: ...156 Fig 12 16 E merge electric motor speed sensor ...

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