88
19.
Apply four equally spaced drops of Penetrox
around each terminal stud on the bus bar. (
Fig. 14
)
20.
Starting with the green motor lead, attach the
ring terminal on the right terminal stud (left as you’re
looking at it). Place a flat washer (part no. 2901674), a
Belleville washer (concave side facing the controller),
and the nut on the stud.
21.
Secure the ziptie, and tighten the nut to 3.5 Nm.
22.
Repeat Steps 20 and 21 for the red motor lead
(center) and black motor lead (left). (
Fig. 15
)
23.
Plug in the connectors for the thermistor (
A
)
and the position sensor (
B
). Make sure they click
into place. (
Fig. 16
)
24.
Check the condition of the insulator on the back of
the motor controller cover, and replace it if necessary
(PN 2102306-00). Affix the insulator to the cover with
three pieces of double-sided tape. (
Fig. 17
)
25.
Feed the LV connector receptacle back through
the cover, and insert the U-lock to lock into place.
26.
Install the cover and tighten the screws in the
sequence indicated to 2 Nm. Apply Loctite 243.
These screws are one-time use, self-sealing fasteners
that must be discarded once removed and replaced
with new screws.
Fig. 15
Fig. 14
Fig. 17
Fig. 16
CHAPTER 6
