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4-9

dummyhead

TROUBLESHOOTING

3A422

Charge

overcurrent

protection

Excessive current flows in

battery, so that does not

activate battery pack by

itself

1. Battery indicator (single

part)

ERROR (Red) indicator

of battery pack stays on,

pressing check button

2. Battery connector

terminals

Any foreign material in

connector (+)/(–)

Excessive current flows in

battery due to battery

charger shorted or

malfunction resulting in

battery not being charged

3. Charger connector

terminals

Any foreign material in

connector (+)/(–)

4. Battery charger (battery

pack installed)

Charger does not start

charging

5. Battery indicator (battery

pack installed on charger)

ERROR (Red) indicator

of battery pack stays on

during charging

6. Charger indicator

ERROR (Red) indicator

of charger stays on

during charging

Damaged battery

7. Battery pack

Replace battery pack

3A423

Pre-charge

overcurrent

protection

Excessive current flows in

battery, so that does not

activate battery pack by

itself

1. Battery indicator (single

part)

ERROR (Red) indicator

of battery pack stays on,

pressing check button

Excessive current flows in

battery due to battery

charger shorted or

malfunction resulting in

battery not being charged

2. Battery charger (battery

pack installed)

Charger does not start

charging

3. Battery indicator (battery

pack installed on charger)

ERROR (Red) indicator

of battery pack stays on

during charging

4. Charger indicator (battery

pack installed)

ERROR (Red) indicator

of charger stays on

during charging

Damaged battery

5. Battery pack

Replace battery pack

3A424

Discharge

overcurrent

protection

Excessive current flows in

battery, so that does not

activate battery pack by

itself

1. Battery current (connected

with Dr. H)

Battery current is 60 A or

2. Battery indicator (single

part)

ERROR (Red) indicator

of battery pack stays on,

pressing check button

3. Battery connector

terminals

Any foreign material in

connector (+)/(–)

Excessive current flows in

battery due to PDU or

related wire shorted

resulting in battery not

being discharged

4. PDU (battery pack

installed on power unit)

Motor operation by

performing the starting

procedure

5. PDU (power unit indicator)

(battery pack installed on

power unit)

ERROR (Red) or ALERT

(Orange) indicator of

power unit flashes

6. Battery indicator (battery

pack installed on power

unit)

ERROR (Red) indicator

of battery pack stays on

during running

7. Power lines of PDU

Any foreign material in

3P (Black) connector (+)/

(–) or line short-circuit

Battery cannot be

discharged due to

excessive load

8. Driven mechanism

Mechanical lock or

excessive overload

Damaged battery

9. Battery pack

Replace battery pack

DTC

Detecting Item

Failure Condition/

Possible Cause

Verification Item (Check in numerical order)

Applicable Part

Check for

(abnormal symptom)

Содержание GXE2.0H

Страница 1: ...you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and using safety equipment When performing any service task be especially careful of the following Read all of the instructions before you begin and make sure you have the tools the replacement or repair parts and the skills required to perform the tasks safely and completely Protect you...

Страница 2: ... table revised page 4 3 Note on indicator indication pattern added page 4 3 Figure of indicator changed page 4 4 Power unit indicator indication pattern table revised page 4 4 Note on indicator indication pattern added page 4 4 Charger indicator indication pattern table revised page 4 5 DTC of power unit added 3A121 3A122 page 4 14 Before removing procedure revised and silent sheet added page 5 2 ...

Страница 3: ...CONTENTS dummyhead dummyhead SPECIFICATIONS 1 SERVICE INFORMATION 2 MAINTENANCE 3 TROUBLESHOOTING 4 COVER 5 CONTROL UNIT 6 POWER UNIT 7 WIRING DIAGRAMS 8 INDEX ...

Страница 4: ... manual Of course it is not practical or possible to warn you about all the hazards associated with servicing these products You must use your own good judgment Honda Motor Co Ltd 2021 You will find important safety information in a variety of forms including Safety Labels on the product Safety Messages preceded by a safety alert symbol and one of three signal words DANGER WARNING or CAUTION These...

Страница 5: ...the hole Metric bolts nuts and screws may be not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the unit SYMBOLS The symbols used throughout this manual show specific service procedures If supplementary information is required pertaining to these symbols it will be explained specifically in the text without the use of the symbols Replace the part s w...

Страница 6: ...iagnostic Trouble Code EACV Electric Air Control Valve EBT Engine Block Temperature ECT Engine Coolant Temperature ECM Engine Control Module EMT Exhaust Manifold Temperature EOP Engine Oil Pressure EX Exhaust F Front or Forward FI Fuel Injection GND Ground HI High HST Hydrostatic Transmission HO2S Heated Oxygen sensor IAB Intake Air Bypass IAC Idle Air Control IAT Intake Air Temperature I D Inside...

Страница 7: ...e this manual SOC State of Charge STD Standard SW Switch TBW Throttle By Wire TDC Top Dead Center TP Throttle Position VST Variable Speed Transmission VTEC Variable Valve Timing Valve Lift Electronic Control Abbreviated term Full term ...

Страница 8: ...MEMO dummyhead dummyhead ...

Страница 9: ...1 1 1 dummytext 1 SPECIFICATIONS SERIAL NUMBER LOCATION 1 2 SPECIFICATIONS 1 2 DIMENSIONAL DRAWINGS 1 4 P T O DIMENSIONAL DRAWINGS 1 6 ...

Страница 10: ...ype S1 S4 S5 Q1 Q2 Q5 Q6 Overall length 294 mm 11 6 in 303 mm 11 9 in Overall width 353 mm 13 9 in Overall height 296 mm 11 7 in 1 420 mm 16 5 in 2 Mass weight 18 5 kg 40 8 lbs 1 25 0 kg 55 1 lbs 2 Model GXE2 0H Type S2 S3 Q3 Q4 Overall length 294 mm 11 6 in 303 mm 11 9 in Overall width 418 mm 16 5 in Overall height 296 mm 11 7 in 1 420 mm 16 5 in 2 Mass weight 19 7 kg 43 4 lbs 1 26 2 kg 57 8 lbs ...

Страница 11: ...unterclockwise viewed from P T O shaft end Cooling system Forced air Breather system Air open type Stopping system Regenerative brake resistant consumption Rotor sensor Hall IC rotation sensor thermistor temperature sensor built in PDU Type 3 phase square wave drive Control system PWM Pulse Width Modulation Maximum 3 phase output current 80 A Cooling system Air cooled Battery pack Type DP72104Z Li...

Страница 12: ...CIFICATIONS DIMENSIONAL DRAWINGS P T O type page 1 3 Without Control Box Unit mm in 353 13 9 162 6 4 38 2 1 50 296 11 7 420 16 5 106 4 2 314 12 4 66 2 6 77 5 3 05 115 4 5 238 9 4 S type 294 11 6 Q type 303 11 9 P T O Q type shown ...

Страница 13: ...ummyhead dummyhead SPECIFICATIONS With Control Box Unit mm in 418 16 5 162 6 4 38 2 1 50 296 11 7 420 16 5 106 4 2 314 12 4 66 2 6 77 5 3 05 180 7 1 238 9 4 S type 294 11 6 Q type 303 11 9 P T O Q type shown ...

Страница 14: ...2 places 4 73 4 78 0 186 0 188 61 5 2 42 45 5 1 79 16 26 16 36 0 640 0 644 Φ19 025 19 050 0 7490 0 7500 31 1 2 40 5 1 59 65 1 2 56 62 2 4 60 2 4 75 3 0 50 2 0 50 2 0 65 1 2 56 37 1 5 25 1 0 68 2 7 M8 x 1 25 9 places Q type Φ22 0 9 23 0 9 5 000 5 030 0 1969 0 1980 53 2 1 35 1 4 14 9 15 0 0 587 0 591 Φ17 957 18 016 0 7070 0 7093 S type M8 x 1 25 ...

Страница 15: ...2 1 2 dummytext 2 SERVICE INFORMATION MAINTENANCE STANDARDS 2 2 TORQUE VALUES 2 2 LUBRICATION SEAL POINT 2 2 TOOLS 2 3 HARNESS ROUTING 2 4 ...

Страница 16: ...stener lever wire bolt M6 x 1 0 10 1 0 7 Harness clip bracket bolt M6 x 1 0 10 1 0 7 Battery connector stay bolt M5 x 0 8 5 9 0 6 4 4 Special collar at PDU stay C M8 x 1 25 27 2 8 20 Top cover bolt M6 x 1 0 8 0 8 5 9 Control cover screw With control box M5 x 1 8 1 7 0 2 1 3 Speed volume switch nut Variable speed type M10 x 0 75 1 1 0 1 0 8 Speed volume switch bracket screw Variable speed type with...

Страница 17: ...2 3 dummyhead dummyhead SERVICE INFORMATION TOOLS Special tools used in this manual can be ordered using normal Honda parts ordering procedures Cooling fan holder 070PB 8A00100 Rotor guide 070PG 8A00100 ...

Страница 18: ...ATTERY 4P White CONNECTOR ROTOR SENSOR 8P Black CONNECTOR PDU 3P Black CONNECTOR POWER CABLE Align JOINT CONNECTOR BRACKET BAND CLIP 3 10 mm 0 1 0 4 in 3 10 mm 0 1 0 4 in BRACKET Align holes with pins 4 places MAIN WIRE HARNESS SWITCH INDICATOR 20P Gray CONNECTOR Make sure that the wire does not interfere with the clip nut on the front cover ...

Страница 19: ...ERVICE INFORMATION 3 PHASE WIRE HARNESS PDU 3P Gray CONNECTOR SIDE FRAME CONTROL WIRE HARNESS Without Control Box shown BANDS Secure with white tape position 3 PHASE WIRE HARNESS ROTOR SENSOR WIRE HARNESS Installation page 7 3 ...

Страница 20: ... of the band on the wire harness and install with the round side facing the case SPEED VOLUME SWITCH 3P Black CONNECTOR Variable speed type Fixed speed type 3P Dummy Connector ALERT INDICATOR POWER INDICATOR CONNECTOR ALERT INDICATOR CONNECTOR Yellow tape on wires ERROR INDICATOR CONNECTOR Red tape on wires 2P Black CONNECTORS Viewed from lower side POWER SWITCH CONNECTOR POWER INDICATOR BRACKET B...

Страница 21: ...ICE INFORMATION STATOR ASSEMBLY ROTOR SENSOR built into stator Red White Blue GROMMETS STAYS 3 PHASE WIRE HARNESS ROTOR SENSOR WIRE HARNESS Inside of motor housing P T O side Do not bite the stator side wire tubes into the grommet ...

Страница 22: ...MEMO dummyhead dummyhead ...

Страница 23: ...3 1 3 dummytext 3 MAINTENANCE MAINTENANCE SCHEDULE 3 2 BEFORE OPERATION CHECK 3 3 VIBRATION DAMPING STRUCTURE COMPONENTS 3 3 WIRE HARNESS CHECK 3 3 DRAIN HOLE CLEANING 3 4 MOTOR SET SPEED CHECK 3 4 ...

Страница 24: ...spected by your servicing dealer 4 Replace if necessary Item REGULAR SERVICE PERIOD 1 Refer to page Each use Every 5 years or 500 hrs Exterior cover Check 3 3 Switch Speed control lever applicable type Check 3 3 LED applicable type Check 3 3 Power cable Check 3 3 Set of wire harnesses Check 2 4 3 3 Battery fastener Check 3 3 Replace 2 5 4 Battery mount rubber Check 3 3 Replace 2 5 4 Battery hook C...

Страница 25: ...k the setting condition of the battery pack and If it feels loose the fastening components must be checked page 5 6 DURING THE TEST RUN Check that the following applicable type All indicators light when the power unit is turned on All switches work properly VIBRATION DAMPING STRUCTURE COMPONENTS NOTE Replace the parts related to the vibration damping mount i e mount rubbers stopper pin bolts stopp...

Страница 26: ...HECK Check that there is no malfunction or unusual sound by rotating and stopping the motor The rotational speed of the motor is set at a constant speed for the fixed speed type For the variable speed type check the rotational speed is adjustable with the speed control lever and that the speed varies smoothly If any abnormality is found follow the troubleshooting page 4 2 1 ...

Страница 27: ...4 1 4 dummytext 4 TROUBLESHOOTING TROUBLESHOOTING INFORMATION 4 2 DTC TROUBLESHOOTING 4 6 ...

Страница 28: ... Dr H for diagnosis Dr H INFORMATION Refer to the Instruction Manual for the Dr H for the connection method to a personal computer and for the step up method How to connect Dr H to power unit Stop the power unit system all the indicators are turn off state Remove the front cover page 5 2 Release the DLC 1 from the stay and remove its dummy connector 2 Connect the 4P connector 3 of the Dr H to the ...

Страница 29: ...tection detection or 5 seconds have elapsed from pressing check button or Cancels protection function Cell low temperature protection at discharging Flash Cell high temperature protection at charging Flash Cell low temperature protection at charging Flash Error Level 1 C FET high temperature protection Flash D FET high temperature protection Flash Overvoltage protection Flash 4 segments Flash Unde...

Страница 30: ...re Stop Flash CAN communication interruption Stop Flash Rotor sensor failure Stop Flash Output pulse abnormality Stop Flash Pre charge circuit failure Stop Flash FET thermistor shorted opened Stop Flash Motor thermistor shorted opened Stop Flash Error FET overtemperature abnormality Stop Flash Motor overtemperature abnormality Stop Flash Motor lock failure Stop Flash Motor overspeed Except S1 Q1 Q...

Страница 31: ...e charging Stay on AC plug connection Power on AC plug disconnection Power off Charging Stay on Charging completed Stay on Error Charger output overvoltage Stay on When detects protection function item or Protection state continued AC plug disconnection Power off Charger output current abnormality Stay on Charger output low voltage abnormality Stay on Charger temperature abnormality Stay on Charge...

Страница 32: ... abnormality permanent failure Battery cannot supply power 1 Battery connectors at battery pack and power cable Any foreign material short circuit failure or other problem in connector 2 Battery cell voltage connected with Dr H Excessive voltage difference between respective cells 3 Battery indicator single part ERROR Red indicator of battery pack flashes pressing check button 4 PDU battery pack i...

Страница 33: ...emperature is 130 C 266 F or more 3 Battery indicator single part ERROR Red indicator of battery pack flashes pressing check button 4 PDU battery pack installed on power unit Motor operation by performing the starting procedure Damaged battery 5 Battery pack Replace battery pack 3A412 Battery thermistor opened permanent failure Line open circuit failure due to thermistor damaged resulting in batte...

Страница 34: ...icator of battery pack flashes pressing check button Abnormal battery cell voltage due to PDU malfunction 3 PDU battery pack installed on power unit Motor operation by performing the starting procedure 4 PDU power unit indicator battery pack installed on power unit ERROR Red or ALERT Orange indicator of power unit flashes Abnormal battery cell voltage due to battery charger malfunction 5 Battery c...

Страница 35: ...ery indicator battery pack installed on charger ERROR Red indicator of battery pack stays on during charging 4 Charger indicator battery pack installed ERROR Red indicator of charger stays on during charging Damaged battery 5 Battery pack Replace battery pack 3A424 Discharge overcurrent protection Excessive current flows in battery so that does not activate battery pack by itself 1 Battery current...

Страница 36: ... or not 3 Battery charger battery pack installed Charger does not start charging 4 Charger indicator battery pack installed ERROR Red indicator of charger stays on during charging FET heats due to high temperature around battery 5 Battery peripheral area installed on charger Peripheral temperature is more than 50 C 122 F Charger cooling fan stops due to foreign object interference or fan motor con...

Страница 37: ...r unit ALERT Orange indicator of power unit flashes during discharging POWER button pressed to ON Battery cannot be discharged due to high ambient temperature 5 Battery peripheral area installed on power unit Peripheral temperature is more than 50 C 122 F Battery cannot be discharged due to excessive load 6 Driven mechanism Mechanical lock or excessive overload Damaged battery 7 Battery pack Repla...

Страница 38: ...or less Damaged battery 6 Battery pack Replace battery pack 3A443 Battery cell low temperature protection at discharging Battery cell overcools resulting in battery not being activated by itself 1 Battery cell temperature connected with Dr H Cell temperature is 20 C 4 F or less 2 Battery indicator single part ALERT Orange indicator of battery pack flashes pressing check button PDU malfunction 3 PD...

Страница 39: ...TOP switch malfunction Loosely connected connector 1 START STOP switch connector Loose or poor connection Loosely connected connector terminals 2 START STOP switch connector terminal Loose or poor contact Open circuit in switch wire 3 Switch wires between switch and PDU Open circuit Damaged PDU 4 PDU Replace PDU 3A106 Regenerative resistance circuit malfunction Damaged PDU 1 PDU Replace PDU 3A107 ...

Страница 40: ...tion of terminal or connector 3A130 FETovercurrent OC2 Overload operation 1 PDU connected with Dr H Current value is 35 A or more in motor running status abnormal High ambient temperature around product 2 PDU mounting area Peripheral temperature Lock or overload by driven system 3 Driven mechanism Mechanical lock or excessive overload Improper installation of PDU on frame 4 PDU PDU mounting condit...

Страница 41: ...normal High ambient temperature around product 2 Motor peripheral area Peripheral temperature Lock or overload by driven system 3 Driven mechanism Mechanical lock or excessive overload Improper installation of PDU on frame 4 PDU PDU mounting condition Damaged PDU 5 PDU Replace PDU 3A142 Motor overheating OT1 Overload operation 1 PDU connected with Dr H Current value is 35 A or more in motor runnin...

Страница 42: ...MEMO dummyhead dummyhead ...

Страница 43: ...5 1 5 dummytext 5 COVER COVER REMOVAL INSTALLATION 5 2 BATTERY TRAY REMOVAL INSTALLATION 5 4 FRAME MOUNT RUBBER CHECK 5 6 BATTERY FASTENING COMPONENT CHECK 5 6 ...

Страница 44: ...LATION Remove the battery pack for the battery tray cover page 7 2 Remove the control box assembly applicable type for the side frame and the rear cover page 6 2 12 mm 0 5 in 1 2 3 4 6 5 8 7 9 10 11 12 13 14 8 N m 0 8 kgf m 5 9 lbf ft 7 5 mm 0 30 in 6 15 NEW ...

Страница 45: ...ty 2 With Control Box Q ty 1 5 BOLT 6 x 16 mm 4 6 SIDE FRAME 7 SPECIAL BOLT 6 x 12 mm 4 8 TOP COVER 9 SPECIAL BOLT 6 x 12 mm 3 10 FRONT COVER 11 SPECIAL BOLT 6 x 12 mm 4 12 PDU COVER 13 SPECIAL BOLT 6 x 12 mm 3 14 REAR COVER 15 SILENT SHEET Except S1 Q1 Q2 types REPLACEMENT Strip the sheet and remove any adhesive from the side frame thoroughly to clean it Peel off the adhesive protective film of a...

Страница 46: ...s page 5 2 Battery tray cover Front cover Rear cover NOTE Before removal check whether the components of the vibration damping structure are normal page 5 6 1 2 6 10 11 12 13 3 4 7 8 9 16 15 14 17 18 19 20 21 5 9 N m 0 6 kgf m 4 4 lbf ft 10 N m 1 0 kgf m 7 lbf ft 10 N m 1 0 kgf m 7 lbf ft 5 ...

Страница 47: ...RING 10 LOCK LEVER PIN 11 FASTENER LEVER 12 SOCKET BOLT 6 x 12 mm 13 FASTENER WIRE INSPECTION page 5 6 14 SOCKET BOLT 6 x 12 mm 15 HARNESS CLIP BRACKET 16 BATTERY MOUNT RUBBER 4 INSPECTION page 5 6 17 HOLE CAP 2 18 NUT 6 mm 8 19 BATTERY FRAME 20 FRAME MOUNT RUBBER 4 INSPECTION Check for cracks or other damage INSTALLATION Align each two locating pins with the holes in the frames 21 STOPPER RUBBER ...

Страница 48: ...bber for damage and measure the rubber height If the rubber is severely damaged or the height is excessively lower than the standard value replace them as a set 2 BATTERY HOOK Looking at the fastener wire from the side as shown check to see whether the hook shape is bent in the direction of the arrows If there is any distortion repair or replace it 3 FASTENER WIRE Looking at the fastener wire from...

Страница 49: ...dummytext 6 CONTROL UNIT CONTROL BOX REMOVAL INSTALLATION Applicable type 6 2 CONTROL BOX DISASSEMBLY ASSEMBLY Applicable type 6 3 PDU REMOVAL INSTALLATION 6 5 PDU MOUNT RUBBER CHECK 6 8 SWITCH INSPECTION 6 8 ...

Страница 50: ... CONTROL BOX REMOVAL INSTALLATION Applicable type Remove the front cover page 5 2 NOTE Route the wire harness properly page 2 4 1 4 3 2 Variable speed type shown Parts Remarks 1 20P Gray CONNECTOR 2 CLIP BAND 3 BOLT 6 x 10 mm 4 4 CONTROL BOX ASSEMBLY ...

Страница 51: ...6 2 NOTE The electrical parts in the control box can be serviced with the control case installed on the power unit Route the wires properly page 2 6 1 7 N m 0 2 kgf m 1 3 lbf ft 1 6 7 2 10 8 15 14 13 16 17 18 19 9 20 24 21 22 23 5 3 4 11 25 1 7 N m 0 2 kgf m 1 3 lbf ft 12 1 1 N m 0 1 kgf m 0 8 lbf ft 18 1 No interference 4 ...

Страница 52: ...mm 2 INSTALLATION Temporarily tighten and then tighten securely with the switch bracket turned clockwise After installing the control lever make sure the lever is not interfered with the control cover 11 VOLUME SWITCH ASSEMBLY 12 NUT 10 mm 13 SWITCH BRACKET 14 SPEED VOLUME SWITCH INSPECTION page 6 9 15 2P Black CONNECTOR 16 POWER SWITCH INSPECTION page 6 8 17 BAND INSTALLATION Secure the three ind...

Страница 53: ...8 NOTICE Do not apply excessive force to the mount rubbers supported PDU during servicing PDU STAY ASSEMBLY 1 4 6 7 3 5 2 27 N m 2 8 kgf m 20 lbf ft Parts Remarks 1 33P Black CONNECTOR 2 3P Gray CONNECTOR 3 3P Black CONNECTOR 4 BOLT 6 x 10 mm 2 5 HARNESS BRACKET B 6 SPECIAL COLLAR 4 7 PDU STAY ASSEMBLY REMOVAL Pull on the stay part gradually by prying the stay at each stud bolt part evenly Do not ...

Страница 54: ...6 6 dummyhead dummyhead CONTROL UNIT STAYS MOUNT RUBBERS 5 6 3 5 2 9 7 1 3 2 8 1 4 3 3 3 ...

Страница 55: ... Parts Remarks 1 STOPPER PIN BOLT 2 INSPECTION Check for wear or other damage 2 NUT 6 mm 4 3 PDU STAY C REMOVAL INSTALLATION Release the lower side by sliding it and then the upper side in sequence as shown to avoid damaging the mount rubbers Installation is in the reverse order 4 NUT 6 mm 4 5 MOUNT RUBBER 4 INSPECTION Check for cracks or other damage INSTALLATION Align the two locating pins with ...

Страница 56: ...ormality is found replace the rubbers and pin bolts as a set Check the stay clearance page 6 7 SWITCH INSPECTION START STOP SWITCH Applicable type Check for continuity between the terminals of the START STOP switch in each switch position shown in the table below POWER SWITCH Applicable type Check for continuity between the terminals of the 2P connector There should be continuity with the switch p...

Страница 57: ...of the switch side 3P connector Check that the resistance between the Red and Green wire terminals varies in accordance with the switch position by operating the speed control lever Turn to right from MIN to MAX Resistance increase Turn to left from MAX to MIN Resistance decrease Standard 4 0 6 0 kΩ Brown Red Green MAX MIN With Control Box ...

Страница 58: ...MEMO dummyhead dummyhead ...

Страница 59: ...7 1 7 dummytext 7 POWER UNIT BATTERY PACK REMOVAL INSTALLATION 7 2 FAN COVER WIRE HARNESS REMOVAL INSTALLATION 7 3 MOTOR REMOVAL INSTALLATION 7 5 MOTOR DISASSEMBLY ASSEMBLY 7 6 STATOR INSPECTION 7 8 ...

Страница 60: ...nector REMOVAL Disconnect the battery connector 1 of the power cable from the battery pack 2 Pull the fastener lever 3 toward you to release the lever pin 4 and then remove the battery pack INSTALLATION Insert the claw 5 of the battery pack into the battery hook 6 securely and set it onto the tray Hook the lever pin and turn the fastener lever over the battery pack to secure it Connect the battery...

Страница 61: ...EMOVAL INSTALLATION Remove all the covers page 5 2 NOTE Route the wire harnesses properly page 2 4 1 10 12 4 6 7 8 15 14 13 16 17 18 19 3 5 2 11 9 20 24 25 21 22 23 5 9 N m 0 6 kgf m 4 4 lbf ft 96 2 5 mm 3 8 0 10 in 3 phase wire harness installation a b c a 21 ...

Страница 62: ...13 BAND 4 14 CLIP BAND 8 15 WIRE CLIP 16 JOINT CONNECTOR 17 DLC 18 8P Black CONNECTOR 19 20P Gray CONNECTOR 20 4P White CONNECTOR 21 3 PHASE WIRE HARNESS including stator INSTALLATION Determine the band a installation position based on the assembled band b in the state of a single item kept straight Install the band a at the position of 96 mm 3 8 in and secure it tightly as shown and make sure it ...

Страница 63: ...LATION Remove the fan cover and the wire harnesses related to the motor page 7 3 4 6 3 5 2 1 7 Parts Remarks 1 NUT 8 mm 3 2 BOLT 8 x 125 mm 3 3 FRAME ASSEMBLY 4 MOTOR 5 BOLT 8 x 20 mm 4 6 MOTOR BASE INSTALLATION Face the concavity 7 to the cooling fan side ...

Страница 64: ...ASSEMBLY ASSEMBLY Remove the motor page 7 5 14 15 16 12 1 5 3 2 4 6 7 8 10 9 17 5 9 N m 0 6 kgf m 4 4 lbf ft 10 N m 1 0 kgf m 7 lbf ft 11 5 9 N m 0 6 kgf m 4 4 lbf ft 13 NEW 10 N m 1 0 kgf m 7 lbf ft Bearing part GREASE 59 N m 6 0 kgf m 44 lbf ft ...

Страница 65: ...s 1 BOLT 5 x 16 mm 2 2 AIR DUCT 3 NUT 12 mm TOOL COOLING FAN HOLDER 070PB 8A00100 page 7 7 4 COOLING FAN 5 WOODRUFF KEY 13 x 12 mm 6 BOLT 6 x 50 mm 8 7 MOTOR HOUSING FAN SIDE INSPECTION Check the dust seal and bearing in the housing for wear or damage 8 DOWEL PIN 2 9 HOUSING PACKING 10 ROTOR SHAFT TOOL ROTOR GUIDE 070PG 8A00100 page 7 8 11 BOLT 5 x 12 mm 4 12 ROTOR FAN 13 SOCKET BOLT 6 x 16 mm 4 1...

Страница 66: ...ove the PDU cover page 5 2 Disconnect the PDU 3P Gray connector 1 Check for connector for loose contacts or corroded terminals Measure the coil resistance between the terminals of the stator side 3P Gray connector Measure the insulation resistance between each connector terminal and the motor housing and rotor shaft with 1 000 VDC range in a insulation resistance tester Replace the stator assembly...

Страница 67: ...8 1 8 dummytext 8 WIRING DIAGRAMS WIRING DIAGRAMS 8 2 ...

Страница 68: ...TTERY 6P Bl 4P W 4P Bu 20P Gr 12P Gr 33P Bl 3P Gr 3P Bl Bl Bu Bu Bu Bu G Bl Bl Bl Bl W Bl G G R P P R W R Bu Bu R R G Bl W Bl Y Y Bu Y R R Bu Bu W W Bl P P Lb Y V Bl Bl Bl Bl W Bl Y Y Bu Y R R Bu P Lb Y V Bu R Bu W Bu Bl Bu P R Bu Bl V Lb P Y R Bl Y Bl Bl Bl Bl P Y Bu Bl Bl W G Lb V R R W Bu Bu Bu Bu G G G Bl Y Bu Bl W Bl W Bl W Bl W Bl W Bl Y Y Bu Bu R Y R Bl Y R G Bl W Bu W Bu Bl R Bu Bl R Bl Y ...

Страница 69: ...u Bu Bu Bu G Bl Bl R G Bl Bl W Bl G G R P P R W R Bu Bu R R G Bl W Bl Y Y Bu Y R R Bu Bu W W Bl P P Lb Y V Bl Bl Bl Br Br Bl W Bl Y Y Bu Y R R Bu P R G Lb Y V Bu R Bu W Bu Bl Bu P R Bu Bl Br R G V Lb Lb Lb P Y R Bl Y Bl Bl Bl Bl P R Y Bu Br Bl Bl W G Lb V R R W Bu Bu Bu Bu G G G G Bl Y Bu Bl W Bl W Bl W Bl W Bl W Bl Y Y Bu Bu R Y R Bl Y R G Bl W Bu W Bu Bl R Bu Br R G Bl R Bl Y Bl Y Bl Y Lb Bl Y V...

Страница 70: ...MEMO dummyhead dummyhead ...

Страница 71: ...RE HARNESS REMOVAL INSTALLATION 7 3 FRAME MOUNT RUBBER CHECK 5 6 H HARNESS ROUTING 2 4 L LUBRICATION SEAL POINT 2 2 M MAINTENANCE SCHEDULE 3 2 MAINTENANCE STANDARDS 2 2 MOTOR DISASSEMBLY ASSEMBLY 7 6 MOTOR REMOVAL INSTALLATION 7 5 MOTOR SET SPEED CHECK 3 4 P P T O DIMENSIONAL DRAWINGS 1 6 PDU MOUNT RUBBER CHECK 6 8 PDU REMOVAL INSTALLATION 6 5 S SERIAL NUMBER LOCATION 1 2 SPECIFICATIONS 1 2 STATOR...

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