Zero SR/S, Service Manual

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20-12 Power Pack
Power Pack 20
Note: You will not be able to put your whole
fingers behind the BMS spacer or circuit
board.
NOTICE: Applying too much force with your
finger behind the BMS circuit board may
cause damage to the BMS.
Note: Do not tighten bolts yet.
14. Torque the BMS header clamp nuts (x2) and
washers (x2). Tool: 7mm socket. Torque:
12 in-lb (1.36 Nm).
Note: Hold header clamp completely still until
both nuts are seated and do not touch the flex
ribbon. Seating the pins in a controlled
manner is critical.
15. If the BMS flex ribbon is not bonded to the
BMS, clean debris from header clamps,
gaskets, and gasket surface. Re-grease
gasket surfaces with CP70.
CAUTION: Before continuing to the next
step, the High Voltage fuses, 12 volt
negative battery cable, and signal harness
must be disconnected.
16. Only thread two turns of the bolts (x2) and flat
washers (x2) securing the header clamp to the
lower battery cell. Tool: T20.
CAUTION:
Before performing this step, the
High Voltage fuses, 12 volt negative battery
cable, and signal harness must be
disconnected.
17. The flex ribbon cable pins may require
realignment during the installation process.
There are three possible positions for the
header clamp (1: up, 2: center, and 3: down).
Align header clamp and use a finger to hold
desired position, then tighten clamp bolts (x2)
and flat washers (x2) evenly.
Note: Tightening bolts evenly keeps the pins
aligned.